Grease compositions having improved performance

ABSTRACT

This disclosure relates to grease compositions having at least one base oil, at least one soap or non-soap thickener, and at least one elastomeric triblock copolymer of the general configuration A-B-A, in which A is a relatively hydrophobic polymer block and B is a relatively hydrophilic polymer block, and in which A forms less than 50% by weight of the total molecular weight of the elastomeric triblock copolymer. When the grease compositions are used under high shear conditions, structural stability and resistance to breaking down in accordance with ASTM D7342 is improved. When the grease compositions are used in low temperature conditions, low temperature starting and running torque in accordance with ASTM D1478 is improved.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 62/781,703 filed Dec. 19, 2018, which is herein incorporated byreference in its entirety.

FIELD

This disclosure relates generally to lubricating compositions andmethods of making and using the same. More specifically, the presentdisclosure relates to polyurea grease compositions with improvedmechanical stability in high shear, hot and wet environments, as well asimproved low temperature properties as measured in starting torque, andmethods of making and using the same. Also, the present disclosurerelates to lithium and lithium complex grease compositions with improvedlow temperature properties as measured in starting and running torque,and methods of making and using the same. The grease compositionsprovide optimum performance in a wide variety of diverse industrial andautomotive applications.

BACKGROUND

Lubricating formulations and greases with a wide assortment of differentmaterials are known. For example, lithium complex greases are known andcan be made from any of a wide variety of base stocks of lubricating oilviscosity, as well as mixtures of base stocks. For example, lithiumcomplex greases that comprise a lithium complex thickener and alubricating base oil are known. Greases have varied levels of desirablegrease characteristics, such as dropping point, penetration, mechanicalstability, shear stability, oxidation resistance, high temperatureresistance, etc., based on its composition. The above characteristicsare used to describe the lubricating life of a particular grease.

High shear resistance is a property desirable in grease for manyindustrial automotive applications; for example, in papermakingmachinery and steel mill machinery. The particular environments,papermaking and steel mill ball bearings, also result in the exposure tohigh temperatures. The exposure to high shear, high temperatures, andwet conditions accelerate the breakdown process of grease compositions.

Currently, lithium soap based greases represent approximately 80% of thelubricating grease market and generally provide acceptable lubricatingperformance. However, lithium soap based greases are limited by theirresistance to high-temperatures, wet environments, and shear.

For example, lithium soap based grease in polyalphaolefin (PAO) basedfluid maxes out at 140° C. Currently available high-temperature lithiumgreases are either composed of solid particles, such aspolytetrafluoroethylene (PTFE), which induce wear and tear on thelubricated surface(s) (such as bearings, gears, slide plates, etc.), orpolyester (POE) base oils, which are costly, are limited in certainproperties and impractical for manufacture.

As technology advances and throughput increases with mechanical devices,there is an increased demand for higher temperature operating conditionsand lubricating compositions, such as grease, with enhanced resistance.This is further compounded by the need for lubricating compositions thatcan effectively function in wet, high shear environments. For example,the environment that ball bearings found in steel mills and paper millsis particularly harsh with high levels of moisture, shear, and heat. Theworking life of grease is limited in such an environment, which resultsin greater wear on the equipment and longer downtimes as a result ofmaintenance (e.g., re-greasing the ball bearings andreplacement/maintenance of warn parts of the equipment).

Thus, a need exists for lubricating greases that have enhanced/extendedhigh temperature resistance that can be utilized in high shear, wetenvironments.

SUMMARY

This disclosure relates in part to grease compositions comprising atleast one base oil, at least one non-soap (e.g., polyurea) thickener,and at least one elastomeric triblock copolymer of the generalconfiguration A-B-A. The A is a relatively hydrophobic polymer block andthe B is a relatively hydrophilic polymer block. The A forms less than50% by weight of the total molecular weight of the elastomeric triblockcopolymer.

When a polyurea grease composition of this disclosure is used under highshear conditions, structural stability and resistance to breaking downin accordance with ASTM D7342 is improved, as compared to structuralstability and resistance to breaking down achieved using a greasecomposition containing other than the polyurea grease composition ofthis disclosure.

When a polyurea grease composition of this disclosure is used in lowtemperature conditions, low temperature starting torque in accordancewith ASTM D1478 is improved, as compared to low temperature startingtorque in accordance with ASTM D1478 achieved using a grease compositioncontaining other than the polyurea grease composition of thisdisclosure.

This disclosure also relates in part to grease compositions comprisingat least one base oil, at least one soap thickener (e.g., lithium soapor lithium salt/soap complex), and at least one elastomeric triblockcopolymer of the general configuration A-B-A. The A is a relativelyhydrophobic polymer block and the B is a relatively hydrophilic polymerblock. The A forms less than 50% by weight of the total molecular weightof the elastomeric triblock copolymer.

When a lithium soap or lithium salt/soap complex grease composition ofthis disclosure is used in low temperature conditions, low temperaturestarting and running torque in accordance with ASTM D1478 is improved,as compared to low temperature starting and running torque in accordancewith ASTM D1478 achieved using a grease composition containing otherthan the lithium soap or lithium salt/soap complex grease composition ofthis disclosure.

This disclosure further relates in part to a method of preparing agrease composition comprising mixing at least one base oil, at least onenon-soap thickener (e.g., polyurea), and at least one elastomerictriblock copolymer of the general configuration A-B-A. The A is arelatively hydrophobic polymer block and the B is a relativelyhydrophilic polymer block. The A forms less than 50% by weight of thetotal molecular weight of the elastomeric triblock copolymer.

This disclosure yet further relates in part to a method of preparing agrease composition comprising mixing at least one base oil, at least onesoap thickener (e.g., lithium soap or lithium salt/soap complex), and atleast one elastomeric triblock copolymer of the general configurationA-B-A. The A is a relatively hydrophobic polymer block and the B is arelatively hydrophilic polymer block. The A forms less than 50% byweight of the total molecular weight of the elastomeric triblockcopolymer.

It has been surprisingly found that, in accordance with this disclosure,polyurea grease compositions containing a small amount (e.g., about 0.5to about 2.5% by weight) of elastomeric triblock copolymer witharchitecture ABA, where A is a relatively hydrophobic polymer block andB is a relatively hydrophilic polymer block, and the A block forms lessthan about 50% by weight of the total molecular weight of theelastomeric triblock copolymer, afford improved performance advantagesin structural stability in high shear, hot and wet environments in theASTM D7342 standard test method, as well as advantage of improved lowtemperature performance as exhibited by a low starting torque for thegrease in the ASTM D1478 standard test method for low temperature torquefor ball bearing grease.

Also, it has been surprisingly found that, in accordance with thisdisclosure, lithium/lithium complex grease compositions containing asmall amount (e.g., about 0.5 to about 2.5% by weight) of elastomerictriblock copolymer with architecture ABA, where A is a relativelyhydrophobic polymer block and B is a relatively hydrophilic polymerblock, and the A block forms less than about 50% by weight of the totalmolecular weight of the elastomeric triblock copolymer, afford improvedlow temperature performance as exhibited by a low starting and runningtorque for the grease in the ASTM D1478 standard test method for lowtemperature torque for ball bearing grease, even though an improvementin structural stability of lithium/lithium complex greases under wet,hot and high shear conditions in the ASTM D7342 standard test method isnot realized.

Other objects and advantages of the present disclosure will becomeapparent from the detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows polyurea grease compositions and test results of wetstructural stability as measured by ASTM D7342, and low temperaturestarting and running torque as measured by ASTM D1478, in accordancewith the Examples.

FIG. 2 shows lithium grease compositions and test results of wetstructural stability as measured by ASTM D7342, and low temperaturestarting and running torque as measured by ASTM D1478, in accordancewith the Examples.

FIG. 3 graphically shows polyurea grease compositions and test resultsof wet structural stability as measured by ASTM D7342 in accordance withthe Examples. The experimental data is from FIG. 1.

FIG. 4 graphically shows polyurea grease compositions and test resultsof low temperature starting torque as measured by ASTM D1478 inaccordance with the Examples. The experimental data is from FIG. 1.

DETAILED DESCRIPTION

All numerical values within the detailed description and the claimsherein are modified by “about” or “approximately” the indicated value,and take into account experimental error and variations that would beexpected by a person having ordinary skill in the art.

The unique grease compositions of this disclosure relate in part topolyurea greases containing a small amount (about 0.5 to about 2.5% byweight) of elastomeric triblock copolymer with architecture ABA, where Ais a relatively hydrophobic polymer block and B is a relativelyhydrophilic polymer block and that A block forms less than about 50% byweight of the total molecular weight of the triblock copolymer.

This disclosure relates in part to polyurea grease compositions withenhanced properties that allow the grease to have improved structuralstability and resistance to breaking down and losing its consistencyunder the effect of high shear and heat in wet conditions. Inparticular, this disclosure describes grease compositions that can allowgrease longer lubricating life in hot, wet and high shear environmentssuch as steel mills and per mills as well as improve lubricatingproperties of grease. More specifically, it has been discovered that theuse of polyurea greases containing elastomeric large molecular weightpolymers surprisingly provide improved structural stability under highshear, hot and wet conditions.

The present disclosure expands the applicability of polyurea greases inhigh shear, hot and wet environments as typically found in paper millsand steel mills roller bearings. In accordance with this disclosure, theability of the polyurea grease to maintain its structure and consistencyeven after use of high shear while exposed to water is enhanced with theinclusion of a small amount of elastomeric triblock copolymer withspecific compositional characteristics.

The polyurea grease compositions of this disclosure also exhibitimprovement in low temperature properties of the grease, morespecifically the low temperature starting torque due to the presence ofa very small amount of the elastomeric triblock copolymer.

The polyurea grease compositions of this disclosure contain a smallamount (e.g., about 0.5 to about 2.5%) of elastomeric triblock copolymerwith architecture ABA, where A is a relatively hydrophobic polymer blockand B is a relatively hydrophilic polymer block, and the A block formsless than about 50% by weight of the total molecular weight of theelastomeric triblock copolymer.

The polyurea grease compositions of this disclosure afford improvedperformance advantages in structural stability in high shear and wetenvironments in the ASTM D7342 standard test method, as well asadvantage of improved low temperature performance as exhibited by a lowstarting torque for the grease in the ASTM D1478 standard test methodfor low temperature torque for ball bearing grease. An advantageprovided by this disclosure is the use of a polyurea grease in highshear and wet environments such as steel mills and paper mills thatallows for longer life of the grease in such environments. Thistranslates to longer equipment run life for the equipment operatorsbetween maintenance and thereby cost savings for them. This alsoimproves reliability of the grease in lubricating the high shearequipment for longer periods of time. Another advantage provided by thisdisclosure is the use of a polyurea grease that provides lower startingtorque requirement and thereby better wear and load protection inapplications where a cold start of the equipment is needed.

In particular, the grease compositions of this disclosure expand theapplicability of polyurea greases in high shear, hot and wetenvironments as typically found in paper mills and steel mills rollerbearings. The grease compositions of this disclosure can also extend thein-service life thereby reducing the need for intermittent servicing ofthe equipment (for replacement of the grease) that the grease is beingused in, while providing adequate lubrication protection to theequipment during the period of use. This advantage in turn increases theproductivity and life of the equipment.

While the ABA triblock copolymers with architecture ABA, where A is arelatively hydrophobic polymer block and B is a relatively hydrophilicpolymer block and that A block forms <50% by weight of the totalmolecular weight of the triblock copolymer, provide excellentimprovement in the wet structural stability of the polyurea greasecompositions, a similar improvement is not realized when these polymersare used together with lithium and lithium complex greases. On the otherhand, when these ABA triblock copolymers are used together with lithiumand lithium complex greases, a surprising improvement in the lowtemperature properties of the lithium and lithium complex grease isrealized. More specifically, the low temperature running torque for thegrease in the ASTM D1478 standard test method for low temperature torquefor ball bearing grease is seen to decrease by nearly an order ofmagnitude with use of small amounts of the ABA triblock copolymer inlithium/lithium complex greases.

An aspect of the present disclosure provides grease compositions withimproved structural stability and resistance to breaking down inaccordance with ASTM D7342, relative to other greases, under extremeconditions, such as high shear conditions in hot, wet environments, thecomposition comprising: at least one base oil, at least one polyureathickener; and at least one elastomeric triblock copolymer.

In any aspect or embodiment described herein, the grease compositionshaving at least one polyurea thickener provide a less than about 50 unitchange in penetration point as determined by ASTM-D7342.

Another aspect of the present disclosure provides grease compositionswith improved low temperature starting torque in accordance with ASTMD1478, the compositions comprising: at least one base oil, at least onepolyurea thickener; and at least one elastomeric triblock copolymer.

Yet another aspect of the present disclosure provides greasecompositions with improved low temperature starting and running torquein accordance with ASTM D1478, the compositions comprising: at least onebase oil, at least one lithium soap or lithium salt/soap complexthickener; and at least one elastomeric triblock copolymer.

In any aspect or embodiment described herein, the grease compositionshave at least one of the following: less than or equal to about 1.25 wt.% of the elastomeric triblock copolymer, about 0.5 wt. % to about 20 wt.% of the thickener, about 50 wt. % to about 90 wt. % of the base oil,less than or equal to about 1 wt. % of additives, or a combinationthereof.

In any aspect or embodiment described herein, the grease composition hasat least one of the following: less than or equal to about 1 wt. % ofthe elastomeric triblock copolymer, about 1 wt. % to about 3 wt. % ofthe thickener, about 70 wt. % to about 85 wt. % of the base oil, lessthan or equal to about 0.25 wt. % of additives, or a combinationthereof.

The grease compositions of this disclosure can be used in automobiles,diesel engines, axles, transmissions, and industrial applications.Grease compositions must meet the specifications for their intendedapplication as defined by the concerned governing organization. Inparticular, the grease compositions of this disclosure provide optimumperformance in a wide variety of diverse industrial and automotiveapplications. For example: electric motors, automotive wheel bearings,paper machine roll bearings (wet and dry), and wind turbines requiredifferent degrees of structural stability and oil release rates,responding to mechanical and thermal stress.

Elastomeric Triblock Copolymers

The elastomeric triblock copolymers used in the disclosure contains atleast two thermodynamically incompatible segments. By the expressionthermodynamically incompatible with respect to the polymers, it is meantthat the polymer contains at least two incompatible segments, forexample, at least one hydrophilic and one hydrophobic segment. Ingeneral, in a triblock copolymer, the ratio of segments is onehydrophobic, one hydrophilic, one hydrophobic or an A-B-A copolymer. Thetriblock copolymers can contain any combination of hydrophobic andhydrophilic segments, provided that there are both hydrophobic andhydrophilic characteristics, and the hydrophobic segments are less thanabout 50 percent by weight of the total molecular weight of the triblockcopolymer. Such polymers are fully described in Kraton™ Polymers GradeRange, www.KRATON.com.

Commercially available thermoplastic rubber type polymers which areespecially useful in forming the compositions of the present disclosureare sold under the trademark Kraton™ by Shell Chemical Company. TheKraton™ rubber polymers are described as elastomers which have anunusual combination of high strength and low viscosity and a uniquemolecular structure of linear triblock copolymers. Each molecule of theKraton™ rubber is said to consist of block segments of styrene monomerunits and rubber monomer and/or comonomer units. Each block segment mayconsist of 100 or more monomer or comonomer units. The most commonstructure for the triblock copolymer is the linear ABA block type,styrene-butadiene-styrene (SBS) and styrene-isoprene-styrene (SIS),which is the Kraton™ D rubber series.

A second polymer of this general type is the Kraton™ G series. Thiscopolymer comprises a styrene-ethylenebutylene-styrene type (S-EB-S)structure. The Kraton™ G series is preferred in the practice of thedisclosure, as the copolymers of this series are hydrogenated and thusmore thermally stable; that is, decomposition is less likely to occurduring blending of the G series polymers with the hydrocarbon (the Dseries polymers having unsaturation within the rubber block).

An illustrative ABA structure of the Kraton™ rubber molecule haspolystyrene end blocks and elastomeric midblocks.

The elastomeric triblock copolymers of this disclosure have a specificgravity from about 0.8 to about 1.0, and a tensile strength of about 400to about 600 psi as measured by ASTM method D-412-tensile jaw testerseparation speed 10 in/min. The elastomeric triblock copolymers of thisdisclosure have a styrene to rubber content of about 20:80 to about40:6029:71, and the Brookfield viscosity is about 8000 (toluenesolution, cps at 77° F., 25% w). The Shore A hardness is about 75.

A preferred triblock polymer is a triblock polymer of the Kraton™ Gtype, in particular Kraton™ G-1650, Kraton™-1650 is a SEBS triblockcopolymer which has a specific gravity of about 0.91, and is said tohave a tensile strength of about 500 psi as measured by ASTM methodD-412-tensile jaw tester separation speed 10 in/min. The styrene torubber content of Kraton™ G-1650 is said by the manufacturer to be about29:71, and the Brookfield viscosity is about 8000 (toluene solution, cpsat 77° F., 25% w). The Shore A hardness is about 75.

The hydrophilic segments are greater than about 50 percent, or greaterthan about 55 percent, or greater than about 60 percent, or greater thanabout 65 percent, or greater than about 70 percent, or greater thanabout 75 percent, or greater than about 80 percent, or greater thanabout 85 percent, or greater than about 90 percent, or greater thanabout 95 percent, by weight of the total molecular weight of thetriblock copolymer, although more or less can often be usedadvantageously.

The hydrophobic segments are less than about 50 percent, or less thanabout 45 percent, or less than about 40 percent, or less than about 35percent, or less than about 30 percent, or less than about 25 percent,or less than about 20 percent, or less than about 15 percent, or lessthan about 10 percent, or less than about 5 percent, by weight of thetotal molecular weight of the triblock copolymer, although more or lesscan often be used advantageously.

The compositions of the present disclosure may include an elastomerictriblock copolymer (e.g., a water-insoluble thickener) in a range fromabout 0.05 to about 20 wt. % (e.g., about 0.05 to about 10 wt. %). Forexample, the grease composition of the present disclosure may havethickener present in an amount of about 0.05 wt. % to about 20 wt. %,about 0.05 wt. % to about 17.5 wt. %, about 0.05 wt. % to about 15 wt.%, about 0.05 wt. % to about 12.5 wt. %, about 0.05 wt. % to about 10wt. %, about 0.05 wt. % to about 7.5 wt. %, about 0.05 wt. % to about 5wt. %, about 0.1 wt. % to about 20 wt. %, about 0.1 wt. % to about 17.5wt. %, about 0.1 wt. % to about 15 wt. %, about 0.1 wt. % to about 12.5wt. %, about 0.1 wt. % to about 10 wt. %, about 0.1 wt. % to about 7.5wt. %, about 0.1 wt. % to about 5 wt. %, about 0.5 wt. % to about 20 wt.%, about 0.5 wt. % to about 17.5 wt. %, about 0.5 wt. % to about 15 wt.%, about 0.5 wt. % to about 12.5 wt. %, about 0.5 wt. % to about 10 wt.%, about 0.5 wt. % to about 7.5 wt. %, about 1 wt. % to about 20 wt. %,about 1 wt. % to about 17.5 wt. %, about 1 wt. % to about 15 wt. %,about 1 wt. % to about 12.5 wt. %, about 1 wt. % to about 10 wt. %,about 1.5 wt. % to about 20 wt. %, about 1.5 wt. % to about 17.5 wt. %,about 1.5 wt. % to about 15 wt. %, about 1.5 wt. % to about 12.5 wt. %,about 2 wt. % to about 20 wt. %, about 2 wt. % to about 17.5 wt. %,about 2 wt. % to about 15 wt. %, about 2.5 wt. % to about 20 wt. %,about 2.5 wt. % to about 17.5 wt. %, or about 2.5 wt. % to about 20 wt.%.

Preferably, the elastomeric triblock copolymer may be used in amounts offrom about 0.05 to about 5 weight percent, or from about 0.1 weightpercent to about 4 weight percent, or from about 0.25 weight percent toabout 3 weight percent, or from about 0.5 weight percent to about 2.5weight percent, based on the total weight of the composition of thepresent disclosure, although more or less can often be usedadvantageously.

Grease Thickeners

The thickener included in a grease composition according to thedisclosure can be a soap or a non-soap thickener.

In an embodiment, the greases of this disclosure having a polyureathickener exhibit improved structural stability and resistance tobreaking down and losing their consistency under the effect of highshear and heat in wet conditions.

In another embodiment, the greases of this disclosure having a lithiumor lithium complex thickener exhibit improvement in low temperatureproperties, particularly a lower starting torque requirement, andthereby better wear and load protection in applications where a coldstart of equipment is needed.

The compositions of the present disclosure may include a thickener(e.g., a water-insoluble thickener) in a range from about 0.5 to about20 wt. % (e.g., about 0.5 to about 10 wt. %). For example, the greasecomposition of the present disclosure may have thickener present in anamount of about 0.5 wt. % to about 20 wt. %, about 0.5 wt. % to about17.5 wt. %, about 0.5 wt. % to about 15 wt. %, about 0.5 wt. % to about12.5 wt. %, about 0.5 wt. % to about 10 wt. %, about 0.5 wt. % to about7.5 wt. %, about 0.5 wt. % to about 5 wt. %, about 1 wt. % to about 20wt. %, about 1 wt. % to about 17.5 wt. %, about 1 wt. % to about 15 wt.%, about 1 wt. % to about 12.5 wt. %, about 1 wt. % to about 10 wt. %,about 1 wt. % to about 7.5 wt. %, about 1 wt. % to about 5 wt. %, about2.5 wt. % to about 20 wt. %, about 2.5 wt. % to about 17.5 wt. %, about2.5 wt. % to about 15 wt. %, about 2.5 wt. % to about 12.5 wt. %, about2.5 wt. % to about 10 wt. %, about 2.5 wt. % to about 7.5 wt. %, about 5wt. % to about 20 wt. %, about 5 wt. % to about 17.5 wt. %, about 5 wt.% to about 15 wt. %, about 5 wt. % to about 12.5 wt. %, about 5 wt. % toabout 10 wt. %, about 7.5 wt. % to about 20 wt. %, about 7.5 wt. % toabout 17.5 wt. %, about 7.5 wt. % to about 15 wt. %, about 7.5 wt. % toabout 12.5 wt. %, about 10 wt. % to about 20 wt. %, about 10 wt. % toabout 17.5 wt. %, about 10 wt. % to about 15 wt. %, about 12.5 wt. % toabout 20 wt. %, about 12.5 wt. % to about 17.5 wt. %, or about 15 wt. %to about 20 wt. %.

The grease compositions of this disclosure will contain an essentiallywater- and oil-insoluble thickener to provide the desired greaseconsistency and structure (cone penetration, dropping point, etc.).Thickeners may be of the soap or non-soap types. Non-soaps are based onorganic or non-organic solids such as bentonite clay, polymers such asthe polyureas or silica aerogels and may be used where their particularproperties so indicate. For example, thickeners for the present greasesare polyureas and the metal salt/soap thickeners, including the complexsoap thickeners based on metals including aluminum, barium, calcium,lithium, sodium. These types of thickeners are well established and aredescribed in numerous publications. See, for example, Boner op cit,Lubricants and Related Products, Klamann, Verlag Chemie, 1984, ISBN3-527-26022-6, ISBN 0-89573-177-0 to which reference is made for adescription of suitable thickeners and the manufacture of greaseincorporating them.

Examples of suitable non-soap thickeners include urea compounds, whichare compounds containing the urea group (—NHCONH—) in their molecularstructure. These compounds include mono-, di-, tri-, tetra- and polyureacompounds, depending upon the number of urea linkages they contain.Polyurea is the preferred thickener for use in the compositions of thisdisclosure. Other suitable non-soap thickeners include clays treatedwith an ammonium compound (for example a tetra-alkyl ammonium halide) torender them hydrophobic, in particular bentonite, attapulgite,hectorite, illite, saponite, sepiolite, biotite, vermiculite, zeoliteclays and the like; silica gels; polymeric thickeners such as PTFE(polytetrafluoroethane) or hydrocarbon polymers such as polypropylene orpolymethylpentene; carbon black; and mixtures thereof.

The thickener may also be a soap-based thickener, typically a metal saltof a fatty acid or mixture of fatty acids or in cases other fattymaterial(s). The soap may for example be an alkali metal salt such as asodium, potassium or lithium salt, or an alkaline earth metal salt suchas a calcium, barium or magnesium salt, or an aluminum salt. It may beselected from lithium, sodium, calcium and aluminum soaps, includingmixed salts such as lithium/calcium soaps. It may in particular be alithium or calcium salt, more particularly a lithium salt.

The soap may be formed by mixing a base such as a metal hydroxide,oxide, carbonate or other such suitable compound with a suitablehydrophobic component, in particular a fatty acid or mixture thereof.The fatty component of the soap will typically have a carbon chainlength of C6-30 or of C12-30, preferably of C6-24 or C12-24, morepreferably of C12-20. Where it is a fatty acid, it may contain otherfunctional groups in addition to the carboxylic acid group, inparticular a hydroxyl group as in, for example 12-hydroxyoctadecanoicacid. Examples of suitably fatty acids include stearic acid,hydroxystearic acid, oleic acid, palmitic acid, myristic acid,cottonseed oil acids and hydrogenated fish oil acids.

Lithium soap thickened greases, for example, have been known for manyyears. Typically, the lithium soaps are derived from C10-24, preferablyC15-18, saturated or unsaturated fatty acids or derivatives thereof. Onesuch derivative is hydrogenated castor oil, which is the glyceride of12-hydroxystearic acid.

A soap thickener may be a metal complex soap, containing a metal salt ofa fatty acid or mixture thereof and an additional complexing agent whichis commonly a low to medium molecular weight acid or dibasic acid or oneof its salts, for example benzoic acid, boric acid or a metal boratesuch as lithium borate. The metal and the fatty acid component may be asdescribed above. The lower molecular weight acid may be a mono-, di- orpolycarboxylic acid, or it may be an inorganic acid such as boric acid.It may be used in the form of an acid salt, such as lithium borate. Thecarboxylic acid may be aromatic or aliphatic and it may contain otherfunctional groups in addition to the carboxylic acid group(s). Inparticular, a metal complex soap may be selected from lithium complex,calcium complex, aluminum complex and calcium sulphonate complex soapsand mixtures thereof.

Complex thickeners of potential use in a grease composition according tothe invention include for example calcium stearate-acetate (see U.S.Pat. No. 2,197,263), barium stearate-acetate (U.S. Pat. No. 2,564,561),calcium stearate-caprylate-acetate complexes (U.S. Pat. No. 2,999,066),and salts of low, intermediate and high molecular weight acids and ofnut oil acids.

Complex grease thickeners are made by combining the conventionalmetallic soaps with a complexing agent. The soaps may be a metal salt ofa long chain fatty acid having from 8 to 24 carbon atoms such asdecanoic acid, myristic acid, palmitic acid or stearic acid. Thethickener may be a lithium or lithium complex thickener thatincorporates a hydroxy fatty acid having from 12 to 24 (e.g., from 16 to20) carbon atoms. For example, the hydroxy fatty acid may be a hydroxystearic acid, e.g., 9-hydroxy or 10-hydroxy stearic acid, or 12-hydroxystearic acid. Other hydroxyl fatty acids which may be used includericinoleic acid (12-hydoxystearic acid unsaturated at the 9,10position), 12-hydroxybehenic acid and 10-hydroxypalmitic acid. Thecomplex salt/soap thickeners are made with a combination of conventionallithium soap such as lithium 12-hydroxystearate and a complexing agentwhich may vary with the type of thickener, e.g. calcium complexthickeners may be formulated with acetic acid and hydroxy-substitutedacids; boric acid may be used with lithium soaps. Low molecular-weightorganic acid, typically C₄ to C₁₂ dibasic acids such as glutaric,azelaic, pimelic, suberic, adipic or sebacic acids, are generallyfavored as the complexing agents with lithium greases. The complexes areformed by the introduction of the complexing agent or its metal saltinto the lattice of the metal salt. Examples of metal salt/soap complexthickeners are described in U.S. Pat. Nos. 3,929,651; 3,940,339;4,410,435; 4,444,669 and 5,731,274. The complexing agent may be added asthe free acid, a salt e.g., the lithium salt or as an ester such as analkyl ester, e.g. methyl glutarate or methyl adipate, which will undergohydrolysis to the acid in the presence of the added alkali, e.g. lithiumhydroxide, to form the complexing agent. PAO bases may require a higherproportion of thickener than mineral oil base stocks.

The lithium complex thickener used in the grease of the presentdisclosure is not particularly limited and can be any lithium complexthickener that is known or that becomes known. For example, the lithiumcomplex thickener can comprise a lithium soap derived from a fatty acidhaving: (a) (i) at least one of an epoxy group, ethylenic unsaturation,or a combination thereof, and (ii) a dilithium salt derived from astraight chain dicarboxylic acid; and/or (b) a lithium salt derived froma hydroxy-substituted carboxylic acid, e.g. salicylic acid.

For example, the lithium complex thickener can comprise at least one of:a complex of a lithium soap of a C₁₂ to C₂₄ hydroxy fatty acid and amonolithium salt of boric acid; a lithium salt of a second hydroxycarboxylic acid, such as salicylic acid; or a combination thereof.

The lithium complex thickener can comprise a lithium soap of a C₁₂ toC₂₄ hydroxy fatty acid thickener antioxidant having an alkali metal saltof hydroxy benzoic acid and a diozime compound. In certain embodiments,the alkali metal salt of hydroxy benzoic acid includes dilithiumsalicylate.

The lithium complex thickener can be a lithium soap comprising at leastone of: a dilithium salt of a C₄ to C₁₂ dicarboxylic acid, e.g.,dilithium azelate; a lithium soap of a 9-, 10- or 12-hydroxy C₁₂ to C₂₄fatty acid, e.g., lithium 12-hydroxy stearate; and a lithium salt formedin-situ in the grease from a second hydroxy carboxylic acid, wherein the—OH group is attached to a carbon atom not more than 6 carbons removedfrom the carboxyl group and either of those groups can be attached toaliphatic portions of the materials or aromatic portions of thematerials.

In any aspect or embodiment described herein, the lithium complexthickener can comprise a complex lithium thickener and at least one of alithium salt of a C₃ to C₁₄ hydroxycarboxylic acid, a thiadiazole, or acombination thereof.

In any aspect or embodiment described herein, the water insolublethickener may include at least one of an aluminum soap, a barium soap, acalcium soap, a lithium soap, an aluminum salt/soap complex, a bariumsalt/soap complex, a calcium salt/soap complex, a lithium salt/soapcomplex, or a combination thereof.

Other thickeners which may be of use in a composition according to theinvention include those disclosed in U.S. Pat. No. 5,650,380,WO-A-1999014292, U.S. Pat. Nos. 6,642,187 and 5,612,297.

In any aspect or embodiment described herein, the water insolublethickener may include at least one of a polyurea.

A grease composition according to the disclosure may contain more thanone thickener.

Lubricating Base Oils

In any aspect or embodiment described herein, the lubricating base oilor oils comprise at least one of: a Group I oil, a Group II oil (e.g.,at least one of Group II light neutral oil such as a Group II oil with aKV100 of about 4-6 cSt, Group II heavy neutral oil such as a Group IIoil with a KV100 of cST, or a combination thereof), a Group III oil, aGroup IV oil, a Group V oil, a gas-to-liquid oil, a polyalphaolefin, orcombinations thereof. For example, the lubricating base oil or oilsinclude at least one Group I oil, Group II oil, mineral oil, or acombination thereof. Lubricating oil may be present in the compositionof present disclosure in an amount of about 50 to about 90 wt. % (e.g.from about 70 to about 85 wt. %) of the grease composition. For example,the grease composition of the present disclosure may include about 50wt. % to about 90 wt. %, about 50 wt. % to about 85 wt. %, about 50 wt.% to about 80 wt. %, about 50 wt. % to about 75 wt. %, about 50 wt. % toabout 70 wt. %, about 50 wt. % to about 65 wt. %, about 50 wt. % toabout 60 wt. %, about 55 wt. % to about 90 wt. %, about 55 wt. % toabout 85 wt. %, about 55 wt. % to about 80 wt. %, about 55 wt. % toabout 75 wt. %, about 55 wt. % to about 70 wt. %, about 55 wt. % toabout 65 wt. %, about 60 wt. % to about 90 wt. %, about 60 wt. % toabout 85 wt. %, about 60 wt. % to about 80 wt. %, about 60 wt. % toabout 75 wt. %, about 60 wt. % to about 70 wt. %, about 65 wt. % toabout 90 wt. %, about 65 wt. % to about 85 wt. %, about 65 wt. % toabout 80 wt. %, about 65 wt. % to about 75 wt. %, about 70 wt. % toabout 90 wt. %, about 70 wt. % to about 85 wt. %, about 70 wt. % toabout 80 wt. %, about 75 wt. % to about 90 wt. %, about 75 wt. % toabout 85 wt. %, or about 80 wt. % to about 90 wt. %.

Groups I, II, III, IV and V are broad base oil stock categories, thecharacteristics of which are summarized in Table 1 below, developed anddefined by the American Petroleum Institute (API Publication 1509;www.API.org) to create guidelines for lubricant base oils. Group I basestocks have a viscosity index of between about 80 to about 120 andcontain greater than about 0.03% sulfur and/or less than about 90%saturates. Group II base stocks have a viscosity index of between about80 to about 120, and contain less than or equal to about 0.03% sulfurand greater than or equal to about 90% saturates. Group III stocks havea viscosity index greater than about 120 and contain less than or equalto about 0.03% sulfur and greater than about 90% saturates. Group IVincludes polyalphaolefins (PAO). Group V base stock includes base stocksnot included in Groups I-IV.

TABLE 1 Properties of Base Oil Groups Base Oil Properties SaturatesSulfur Viscosity Index Group I <90 and/or >0.03% and ≥80 and <120 GroupII ≥90 and ≤0.03% and ≥80 and <120 Group III ≥90 and ≤0.03% and ≥120Group IV polyalphaolefins (PAO) Group V All other base oil stocks notincluded in Groups I, II, III or IV

Natural oils include animal oils, vegetable oils (castor oil and lardoil, for example), and mineral oils. Animal and vegetable oilspossessing favorable thermal oxidative stability can be used. Of thenatural oils, mineral oils are preferred. Mineral oils vary widely as totheir crude source, for example, as to whether they are paraffinic,naphthenic, or mixed paraffinic-naphthenic. Oils derived from coal orshale are also useful. Natural oils vary also as to the method used fortheir production and purification, for example, their distillation rangeand whether they are straight run or cracked, hydrorefined, or solventextracted.

Group II and/or Group III hydroprocessed or hydrocracked base stocks arealso well known base stock oils.

Synthetic oils include hydrocarbon oil. Hydrocarbon oils include oilssuch as polymerized and interpolymerized olefins (polybutylenes,polypropylenes, propylene isobutylene copolymers, ethylene-olefincopolymers, and ethylene-alphaolefin copolymers, for example).Polyalphaolefin (PAO) oil base stocks are commonly used synthetichydrocarbon oil. By way of example, PAOs derived from C₈, C₁₀, C₁₂, C₁₄olefins or mixtures thereof may be utilized. See U.S. Pat. Nos.4,956,122; 4,827,064; and 4,827,073.

The average molecular weights of the PAOs, which are known materials andgenerally available on a major commercial scale from suppliers such asExxonMobil Chemical Company, Chevron Phillips Chemical Company, BP, andothers, can vary from about 250 to about 3,000, although PAO's may bemade in viscosities up to about 150 cSt (100° C.). The PAOs aretypically comprised of relatively low molecular weight hydrogenatedpolymers or oligomers of alphaolefins which include, but are not limitedto, C₂ to about C₃₂ alphaolefins with the C₈ to about C₁₆ alphaolefins,such as 1-octene, 1-decene, 1-dodecene and the like. For example, thepolyalphaolefins can be poly-1-octene, poly-1-decene, poly-1-dodecene, acombination thereof, or mixed olefin-derived polyolefins. However, thedimers of higher olefins in the range of C₁₂ to C₁₈ may be used toprovide low viscosity base stocks of acceptably low volatility.Depending on the viscosity grade and the starting oligomer, the PAOs maybe predominantly dimers, trimers and tetramers of the starting olefins,with minor amounts of the lower and/or higher oligomers, having aviscosity range of 1.5 cSt to 12 cSt. PAO fluids of particular use mayinclude 3 cSt, 3.4 cSt, and/or 3.6 cSt and combinations thereof.Mixtures of PAO fluids having a viscosity range of 1.5 cSt toapproximately 150 cSt or more may be used if desired. Unless indicatedotherwise, all viscosities cited herein are measured at 100° C.

The PAO fluids may be conveniently made by the polymerization of analphaolefin in the presence of a polymerization catalyst such as theFriedel-Crafts catalysts including, for example, aluminum trichloride,boron trifluoride or complexes of boron trifluoride with water, alcoholssuch as ethanol, propanol or butanol, carboxylic acids or esters such asethyl acetate or ethyl propionate. For example the methods disclosed byU.S. Pat. No. 4,149,178 or 3,382,291 may be conveniently used herein.Other descriptions of PAO synthesis are found in the following U.S. Pat.Nos. 3,742,082; 3,769,363; 3,876,720; 4,239,930; 4,367,352; 4,413,156;4,434,408; 4,910,355; 4,956,122; and 5,068,487. The dimers of the C₁₄ toC₁₈ olefins are described in U.S. Pat. No. 4,218,330.

Other useful lubricant oil base stocks include wax isomerate base stocksand base oils, comprising hydroisomerized waxy stocks (e.g. waxy stockssuch as gas oils, slack waxes, fuels hydrocracker bottoms, etc.),hydroisomerized Fischer-Tropsch waxes, Gas-to-Liquids (GTL) base stocksand base oils, and other wax isomerate hydroisomerized base stocks andbase oils, or mixtures thereof. Fischer-Tropsch waxes, the high boilingpoint residues of Fischer-Tropsch synthesis, are highly paraffinichydrocarbons with very low sulfur content. The hydroprocessing used forthe production of such base stocks may use an amorphoushydrocracking/hydroisomerization catalyst, such as one of thespecialized lube hydrocracking (LHDC) catalysts or a crystallinehydrocracking/hydroisomerization catalyst, such as a zeolitic catalyst.For example, one useful catalyst is ZSM-48 as described in U.S. Pat. No.5,075,269, the disclosure of which is incorporated herein by referencein its entirety. Processes for making hydrocracked/hydroisomerizeddistillates and hydrocracked/hydroisomerized waxes are described, forexample, in U.S. Pat. Nos. 2,817,693; 4,975,177; 4,921,594 and 4,897,178as well as in British Patent Nos. 1,429,494; 1,350,257; 1,440,230 and1,390,359. Each of the aforementioned patents is incorporated herein intheir entirety. Particularly favorable processes are described inEuropean Patent Application Nos. 464546 and 464547, also incorporatedherein by reference. Processes using Fischer-Tropsch wax feeds aredescribed in U.S. Pat. Nos. 4,594,172 and 4,943,672, the disclosures ofwhich are incorporated herein by reference in their entirety.

Gas-to-Liquids (GTL) base oils, Fischer-Tropsch wax derived base oils,and other wax-derived hydroisomerized (wax isomerate) base oils may beused in the present disclosure, and may have kinematic viscosities at100° C. of about 2 cSt to about 50 cSt, e.g. about 2 cSt to about 30 cStor about 3 cSt to about 25 cSt, as exemplified by GTL 4 with kinematicviscosity of about 4.0 cSt at 100° C. and a viscosity index of about141. These Gas-to-Liquids (GTL) base oils, Fischer-Tropsch wax derivedbase oils, and other wax-derived hydroisomerized base oils may haveuseful pour points of about −20° C. or lower, and under some conditionsmay have advantageous pour points of about −25° C. or lower, with usefulpour points of about −30° C. to about −40° C. or lower. Usefulcompositions of Gas-to-Liquids (GTL) base oils, Fischer-Tropsch waxderived base oils, and wax-derived hydroisomerized base oils are recitedin U.S. Pat. Nos. 6,080,301; 6,090,989, and 6,165,949 for example, andare incorporated herein in their entirety by reference.

The hydrocarbyl aromatics can be used as a base oil or base oilcomponent and can be any hydrocarbyl molecule in which at least about 5%of its weight is derived from an aromatic moiety, such as a benzenoidmoiety or naphthenoid moiety, or their derivatives. These hydrocarbylaromatics include alkyl benzenes, alkyl naphthalenes, alkyl biphenyls,alkyl diphenyl oxides, alkyl naphthols, alkyl diphenyl sulfides,alkylated bis-phenol A, alkylated thiodiphenol, and the like. Thearomatic can be mono-alkylated, dialkylated, polyalkylated, and thelike. The aromatic can be mono-functionalized or poly-functionalized.The hydrocarbyl groups can also be comprised of mixtures of alkylgroups, alkenyl groups, alkynyl, cycloalkyl groups, cycloalkenyl groupsand other related hydrocarbyl groups. The hydrocarbyl groups can rangefrom about C₆ up to about C₆₀ with a range of about C₈ to about C₂₀often being preferred. A mixture of hydrocarbyl groups may be utilized,and up to about three such substituents may be present. The hydrocarbylgroup can optionally contain sulfur, oxygen, and/or nitrogen containingsubstituents. The aromatic group can also be derived from natural(petroleum) sources, provided at least about 5% of the molecule iscomprised of an above-type aromatic moiety. In certain embodiments, theviscosity at 100° C. is approximately 2 cSt to about 50 cSt, e.g.approximately 3 cSt to about 20 cSt for the hydrocarbyl aromaticcomponent. In one embodiment, an alkyl naphthalene where the alkyl groupis primarily comprised of 1-hexadecene is used. Other alkylates ofaromatics can be advantageously used. Naphthalene or methyl naphthalene,for example, can be alkylated with olefins such as octene, decene,dodecene, tetradecene or higher, mixtures of similar olefins, and thelike. Alkylated naphthalene and analogues may also comprise compositionswith isomeric distribution of alkylating groups on the alpha and betacarbon positions of the ring structure. Distribution of groups on thealpha and beta positions of a naphthalene ring may range from 100:1 to1:100, more often 50:1 to 1:50 Useful concentrations of hydrocarbylaromatic in a lubricant oil composition can be about 2% to about 25%,e.g. about 4% to about 20% or about 4% to about 15%, depending on theapplication.

Alkylated aromatics such as the hydrocarbyl aromatics of the presentdisclosure may be produced by well-known Friedel-Crafts alkylation ofaromatic compounds. See Friedel-Crafts and Related Reactions, Olah, G.A. (ed.), Inter-science Publishers, New York, 1963. For example, anaromatic compound, such as benzene or naphthalene, is alkylated by anolefin, alkyl halide or alcohol in the presence of a Friedel-Craftscatalyst. See Friedel-Crafts and Related Reactions, Vol. 2, part 1,chapters 14, 17, and 18, See Olah, G. A. (ed.), Inter-sciencePublishers, New York, 1964. Many homogeneous or heterogeneous, solidcatalysts are known to one skilled in the art. The choice of catalystdepends on the reactivity of the starting materials and product qualityrequirements. For example, strong acids such as AlCl₃, BF₃, or HF may beused. In some cases, milder catalysts such as FeCl₃ or SnCl₄ arepreferred. Newer alkylation technology uses zeolites or solid superacids.

Esters comprise a useful base stock. Additive solvency and sealcompatibility characteristics may be secured by the use of esters suchas the esters of dibasic acids with monoalkanols and the polyol estersof monocarboxylic acids. Esters of the former type include, for example,the esters of dicarboxylic acids such as phthalic acid, succinic acid,alkyl succinic acid, alkenyl succinic acid, maleic acid, azelaic acid,suberic acid, sebacic acid, fumaric acid, adipic acid, linoleic aciddimer, malonic acid, alkyl malonic acid, alkenyl malonic acid, etc.,with a variety of alcohols such as butyl alcohol, hexyl alcohol, dodecylalcohol, 2-ethylhexyl alcohol, etc. Specific examples of these types ofesters include dibutyl adipate, di(2-ethylhexyl) sebacate, di-n-hexylfumarate, dioctyl sebacate, diisooctyl azelate, diisodecyl azelate,dioctyl phthalate, didecyl phthalate, dieicosyl sebacate, etc.

Useful synthetic esters are those which are obtained by reacting one ormore polyhydric alcohols, such as hindered polyols (including theneopentyl polyols, e.g., neopentyl glycol, trimethylol ethane,2-methyl-2-propyl-1,3-propanediol, trimethylol propane, pentaerythritoland dipentaerythritol) with alkanoic acids containing at least about 4carbon atoms, e.g. C₅ to C₃₀ acids such as saturated straight chainfatty acids including caprylic acid, capric acid, lauric acid, myristicacid, palmitic acid, stearic acid, arachic acid, and behenic acid, orthe corresponding branched chain fatty acids or unsaturated fatty acidssuch as oleic acid, or mixtures of any of these materials.

Suitable synthetic ester components include the esters of trimethylolpropane, trimethylol butane, trimethylol ethane, pentaerythritol and/ordipentaerythritol with one or more monocarboxylic acids containing fromabout 5 to about 10 carbon atoms. These esters are widely availablecommercially, for example, the Mobil P-41 and P-51 esters of ExxonMobilChemical Company (Irving, Tex., USA).

Also useful are esters derived from renewable material, such as coconut,palm, rapeseed, soy, sunflower and the like. These esters may bemonoesters, di-esters, polyol esters, complex esters, or mixturesthereof. These esters are widely available commercially, for example,the Esterex NP 343 of ExxonMobil Chemical Company (Irving, Tex., USA).For example, the renewable content of the ester may be greater thanabout 70 weight percent, such as more than about 80 weight percent ormore than about 90 weight percent.

Other useful fluids of lubricating viscosity include non-conventional orunconventional base stocks that have been processed, e.g. catalytically,or synthesized to provide high performance lubrication characteristics.

Non-conventional or unconventional base stocks/base oils include one ormore of a mixture of base stock(s) derived from one or moreGas-to-Liquids (GTL) materials, as well as isomerate/isodewaxate basestock(s) derived from natural wax or waxy feeds, mineral and ornon-mineral oil waxy feed stocks such as slack waxes, natural waxes, andwaxy stocks such as gas oils, waxy fuels hydrocracker bottoms, waxyraffinate, hydrocrackate, thermal crackates, or other mineral, mineraloil, or even non-petroleum oil derived waxy materials such as waxymaterials received from coal liquefaction or shale oil, and mixtures ofsuch base stocks.

GTL materials are materials that are derived via one or more synthesis,combination, transformation, rearrangement, and/ordegradation/deconstructive processes from gaseous carbon-containingcompounds, hydrogen-containing compounds and/or elements as feed stockssuch as hydrogen, carbon dioxide, carbon monoxide, water, methane,ethane, ethylene, acetylene, propane, propylene, propyne, butane,butylenes, and butynes. GTL base stocks and/or base oils are GTLmaterials of lubricating viscosity that are generally derived fromhydrocarbons; for example, waxy synthesized hydrocarbons, that arethemselves derived from simpler gaseous carbon-containing compounds,hydrogen-containing compounds and/or elements as feed stocks. GTL basestock(s) and/or base oil(s) include oils boiling in the lube oil boilingrange (1) separated/fractionated from synthesized GTL materials such as,for example, by distillation and subsequently subjected to a final waxprocessing step which involves either or both of a catalytic dewaxingprocess, or a solvent dewaxing process, to produce lube oils ofreduced/low pour point; (2) synthesized wax isomerates, comprising, forexample, hydrodewaxed or hydroisomerized cat and/or solvent dewaxedsynthesized wax or waxy hydrocarbons; (3) hydrodewaxed orhydroisomerized cat and/or solvent dewaxed Fischer-Tropsch (F-T)material (i.e., hydrocarbons, waxy hydrocarbons, waxes and possibleanalogous oxygenates); such as hydrodewaxed or hydroisomerized/followedby cat and/or solvent dewaxing dewaxed F-T waxy hydrocarbons, orhydrodewaxed or hydroisomerized/followed by cat (or solvent) dewaxingdewaxed, F-T waxes, or mixtures thereof.

GTL base stock(s) and/or base oil(s) derived from GTL materials,especially, hydrodewaxed or hydroisomerized/followed by cat and/orsolvent dewaxed wax or waxy feed, preferably F-T material derived basestock(s) and/or base oil(s), are characterized typically as havingkinematic viscosities at 100° C. of from about 2 mm²/s to about 50 mm²/s(ASTM D445). They are further characterized typically as having pourpoints of −5° C. to about −40° C. or lower (ASTM D97). They are alsocharacterized typically as having viscosity indices of about 80 to about140 or greater (ASTM D2270).

In addition, the GTL base stock(s) and/or base oil(s) are typicallyhighly paraffinic (>90% saturates), and may contain mixtures ofmonocycloparaffins and multicycloparaffins in combination withnon-cyclic isoparaffins. The ratio of the naphthenic (i.e.,cycloparaffin) content in such combinations varies with the catalyst andtemperature used. Further, GTL base stock(s) and/or base oil(s)typically have very low sulfur and nitrogen content, generallycontaining less than about 10 ppm, and more typically less than about 5ppm of each of these elements. The sulfur and nitrogen content of GTLbase stock(s) and/or base oil(s) obtained from F-T material, especiallyF-T wax, is essentially nil. In addition, the absence of phosphorus andaromatics make this materially especially suitable for the formulationof low SAP products.

The term GTL base stock and/or base oil and/or wax isomerate base stockand/or base oil is to be understood as embracing individual fractions ofsuch materials of wide viscosity range as recovered in the productionprocess, mixtures of two or more of such fractions, as well as mixturesof one or two or more low viscosity fractions with one, two or morehigher viscosity fractions to produce a blend wherein the blend exhibitsa target kinematic viscosity.

The GTL material, from which the GTL base stock(s) and/or base oil(s)is/are derived is preferably an F-T material (i.e., hydrocarbons, waxyhydrocarbons, wax).

The grease composition of the present disclosure may use any of thevariety of oils corresponding to API Group I, Group II, Group III, GroupIV, and Group V oils and mixtures thereof, e.g. API Group I oil, APIGroup II oil, mineral oil, or a combination thereof, may be utilized inthe compositions of the present disclosure.

Grease Thickener

The compositions of the present disclosure include a polyurea.

The compositions of the present disclosure include a thickener (e.g., awater-insoluble thickener) in a range from about 0.5 to about 20 wt. %(e.g., about 0.5 to about 10 wt. %. For example, the grease compositionof the present disclosure may have thickener present in an amount ofabout 0.5 wt. % to about 20 wt. %, about 0.5 wt. % to about 17.5 wt. %,about 0.5 wt. % to about 15 wt. %, about 0.5 wt. % to about 12.5 wt. %,about 0.5 wt. % to about 10 wt. %, about 0.5 wt. % to about 7.5 wt. %,about 0.5 wt. % to about 5 wt. %, about 1 wt. % to about 20 wt. %, about1 wt. % to about 17.5 wt. %, about 1 wt. % to about 15 wt. %, about 1wt. % to about 12.5 wt. %, about 1 wt. % to about 10 wt. %, about 1 wt.% to about 7.5 wt. %, about 1 wt. % to about 5 wt. %, about 2.5 wt. % toabout 20 wt. %, about 2.5 wt. % to about 17.5 wt. %, about 2.5 wt. % toabout 15 wt. %, about 2.5 wt. % to about 12.5 wt. %, about 2.5 wt. % toabout 10 wt. %, about 2.5 wt. % to about 7.5 wt. %, about 5 wt. % toabout 20 wt. %, about 5 wt. % to about 17.5 wt. %, about 5 wt. % toabout 15 wt. %, about 5 wt. % to about 12.5 wt. %, about 5 wt. % toabout 10 wt. %, about 7.5 wt. % to about 20 wt. %, about 7.5 wt. % toabout 17.5 wt. %, about 7.5 wt. % to about 15 wt. %, about 7.5 wt. % toabout 12.5 wt. %, about 10 wt. % to about 20 wt. %, about 10 wt. % toabout 17.5 wt. %, about 10 wt. % to about 15 wt. %, about 12.5 wt. % toabout 20 wt. %, about 12.5 wt. % to about 17.5 wt. %, or about 15 wt. %to about 20 wt. %.

The grease will contain an essentially water- and oil-insolublethickener to provide the desired grease consistency and structure (conepenetration, dropping point, etc.). Thickeners may be of the soap ornon-soap types. Non-soaps are based on organic or non-organic solidssuch as bentonite clay, polymers such as the polyureas or silicaaerogels and may be used where their particular properties so indicate.For example, thickeners for the present greases are the metal salt/soapthickeners, including the complex soap thickeners based on metalsincluding aluminum, barium, calcium, lithium, sodium. These types ofthickeners are well established and are described in numerouspublications. See, for example, Boner op cit, Lubricants and RelatedProducts, Klamann, Verlag Chemie, 1984, ISBN 3-527-26022-6, ISBN0-89573-177-0 to which reference is made for a description of suitablethickeners and the manufacture of grease incorporating them.

Complex grease thickeners are made by combining the conventionalmetallic soaps with a complexing agent. The soaps may be a metal salt ofa long chain fatty acid having from 8 to 24 carbon atoms such asdecanoic acid, myristic acid, palmitic acid or stearic acid. Thethickener may be a lithium or lithium complex thickener thatincorporates a hydroxy fatty acid having from 12 to 24 (e.g., from 16 to20) carbon atoms. For example, the hydroxy fatty acid may be a hydroxystearic acid, e.g., 9-hydroxy or 10-hydroxy stearic acid, or 12-hydroxystearic acid. Other hydroxyl fatty acids which may be used includericinoleic acid (12-hydoxystearic acid unsaturated at the 9,10position), 12-hydroxybehenic acid and 10-hydroxypalmitic acid. Thecomplex salt/soap thickeners are made with a combination of conventionallithium soap such as lithium 12-hydroxystearate and a complexing agentwhich may vary with the type of thickener, e.g. calcium complexthickeners may be formulated with acetic acid and hydroxy-substitutedacids; boric acid may be used with lithium soaps. Low molecular-weightorganic acid, typically C₄ to C₁₂ dibasic acids such as glutaric,azelaic, pimelic, suberic, adipic or sebacic acids, are generallyfavored as the complexing agents with lithium greases. The complexes areformed by the introduction of the complexing agent or its metal saltinto the lattice of the metal salt. Examples of metal salt/soap complexthickeners are described in U.S. Pat. Nos. 3,929,651; 3,940,339;4,410,435; 4,444,669 and 5,731,274. The complexing agent may be added asthe free acid, a salt e.g., the lithium salt or as an ester such as analkyl ester, e.g. methyl glutarate or methyl adipate, which will undergohydrolysis to the acid in the presence of the added alkali, e.g. lithiumhydroxide, to form the complexing agent. PAO bases may require a higherproportion of thickener than mineral oil base stocks.

The lithium complex thickener used in the grease of the presentdisclosure is not particularly limited and can be any lithium complexthickener that is known or that becomes known. For example, the lithiumcomplex thickener can comprise a lithium soap derived from a fatty acidhaving: (a) (i) at least one of an epoxy group, ethylenic unsaturation,or a combination thereof, and (ii) a dilithium salt derived from astraight chain dicarboxylic acid; and/or (b) a lithium salt derived froma hydroxy-substituted carboxylic acid, e.g. salicylic acid.

For example, the lithium complex thickener can comprise at least one of:a complex of a lithium soap of a C₁₂ to C₂₄ hydroxy fatty acid and amonolithium salt of boric acid; a lithium salt of a second hydroxycarboxylic acid, such as salicylic acid; or a combination thereof.

The lithium complex thickener can comprise a lithium soap of a C₁₂ toC₂₄ hydroxy fatty acid thickener antioxidant having an alkali metal saltof hydroxy benzoic acid and a diozime compound. In certain embodiments,the alkali metal salt of hydroxy benzoic acid includes dilithiumsalicylate.

The lithium complex thickener can be a lithium soap comprising at leastone of: a dilithium salt of a C₄ to C₁₂ dicarboxylic acid, e.g.,dilithium azelate; a lithium soap of a 9-, 10- or 12-hydroxy C₁₂ to C₂₄fatty acid, e.g., lithium 12-hydroxy stearate; and a lithium salt formedin-situ in the grease from a second hydroxy carboxylic acid, wherein the—OH group is attached to a carbon atom not more than 6 carbons removedfrom the carboxyl group and either of those groups can be attached to a

In any aspect or embodiment described herein, the lithium complexthickener can comprise a complex lithium thickener and at least one of alithium salt of a C₃ to C₁₄ hydroxycarboxylic acid, a thiadiazole, or acombination thereof.

In any aspect or embodiment described herein, the water insolublethickener may include at least one of an aluminum soap, a barium soap, acalcium soap, a lithium soap, an aluminum salt/soap complex, a bariumsalt/soap complex, a calcium salt/soap complex, a lithium salt/soapcomplex, or a combination thereof.

Performance Additives

The composition of the present disclosure may include small amounts ofat least one (e.g., 1, 2, 3, 4, 5, or 6, or more) performance additive.For example, the composition of the present disclosure may include atleast one of anticorrosive agent or corrosion inhibitor, an extremepressure additive, an antiwear agent, a pour point depressants, anantioxidant or oxidation inhibitor, a rust inhibitor, a metaldeactivator, a dispersant, a demulsifier, a dye or colorant/chromophoricagent, a seal compatibility agent, a friction modifier, a viscositymodifier/improver, a viscosity index improver, or combinations thereof.For example, solid lubricants such as molybdenum disulfide and graphitemay be present in the composition of the present disclosure, such asfrom about 1 to about 5 wt. % (e.g., from about 1.5 to about 3 wt. %)for molybdenum disulfide and from about 3 to about 15.wt. % (e.g., fromabout 6 to about 12 wt. %) for graphite.

The amounts of individual additives will vary according to the additiveand the level of functionality to be provided by it.

The presence or absence of these lubricating oil performance additivesdoes not adversely affect the compositions of the present disclosure.For a review of many commonly used additives, see Klamann in Lubricantsand Related Products, Verlag Chemie, Deerfield Beach, Fla.; ISBN 0 89573177 0. Reference is also made to “Lubricant Additives” by M. W. Ranney,published by Noyes Data Corporation of Parkridge, N.J. (1973) and“Lubricant Additives: Chemistry and Applications” edited by L.R.Rudnick, published by CRC Press of Boca Raton, Fla. (2009). Theperformance additives useful in the present disclosure do not have to besoluble in the lubricating oils. Insoluble additives in oil can bedispersed in the lubricating oils of the present disclosure. The typesand quantities of performance additives used in combination with thecompositions of the present disclosure are not limited by the examplesshown herein as illustrations.

As such, in any aspect or embodiment described herein, the compositionfurther comprises at least one of anticorrosive agent or corrosioninhibitor, an extreme pressure additive, an antiwear agent, a pour pointdepressants, an antioxidant or oxidation inhibitor, a rust inhibitor, ametal deactivator, a dispersant, a demulsifier, a dye orcolorant/chromophoric agent, a seal compatibility agent, a frictionmodifier, a viscosity modifier/improver, a viscosity index improver, orcombinations thereof. In any aspect or embodiment described herein, thedispersant includes succinimide-type dispersant. Unless specifiedotherwise, the performance additive or performance additives listedabove are present in a total amount equal to or less than about 10 wt.%, equal to or less than about 9.5 wt. %, equal to or less than about 9wt. %, equal to or less than about 8.5 wt. %, equal to or less thanabout 8 wt. %, equal to or less than about 7.5 wt. %, equal to or lessthan about 7 wt. %, equal to or less than about 6.5 wt. %, equal to orless than about 6 wt. %, equal to or less than about 5.5 wt. %, equal toor less than about 5 wt. %, equal to or less than about 4.5 wt. %, equalto or less than about 4 wt. %, equal to or less than about 3.5 wt. %,equal to or less than about 3 wt. %, equal to or less than about 2.5 wt.%, equal to or less than about 2 wt. %, equal to or less than about 1.5wt. %, or equal to or less than about 0.5 wt. %. For example, theperformance additive or performance additives are present in a totalamount of about 0.1 to about 10 wt. %, about 0.1 to about 9 wt. %, about0.1 to about 8 wt. %, about 0.1 to about 7 wt. %, about 0.1 to about 6wt. %, about 0.1 to about 5 wt. %, about 0.1 to about 4 wt. %, about 0.1to about 3 wt. %, about 0.1 to about 2 wt. %, about 0.1 to about 1 wt.%, about 0.5 to about 10 wt. %, about 0.5 to about 9 wt. %, about 0.5 toabout 8 wt. %, about 0.5 to about 7 wt. %, about 0.5 to about 6 wt. %,about 0.5 to about 5 wt. %, about 0.5 to about 4 wt. %, about 0.5 toabout 3 wt. %, about 0.5 to about 2 wt. %, about 1 to about 10 wt. %,about 1 to about 9 wt. %, about 1 to about 8 wt. %, about 1 to about 7wt. %, about 1 to about 6 wt. %, about 1 to about 5 wt. %, about 1 toabout 4 wt. %, about 1 to about 3 wt. %, about 2 to about 10 wt. %,about 2 to about 9 wt. %, about 2 to about 8 wt. %, about 2 to about 7wt. %, about 2 to about 6 wt. %, about 2 to about 5 wt. %, about 2 toabout 4 wt. %, about 3 to about 10 wt. %, about 3 to about 9 wt. %,about 3 to about 8 wt. %, about 3 to about 7 wt. %, about 3 to about 6wt. %, about 3 to about 5 wt. %, about 4 to about 10 wt. %, about 4 toabout 9 wt. %, about 4 to about 8 wt. %, about 4 to about 7 wt. %, about4 to about 6 wt. %, about 5 to about 10 wt. %, about 5 to about 9 wt. %,about 5 to about 8 wt. %, about 5 to about 7 wt. %, about 6 to about 10wt. %, about 6 to about 9 wt. %, about 6 to about 8 wt. %, about 7 toabout 10 wt. %, about 7 to about 9 wt. %, or about 8 to about 10 wt. %.

When the additives are described below by reference to individualcomponents used in the formulation, they will not necessarily be presentor identifiable as discrete entities in the final product but may bepresent as reaction products which are formed during the greasemanufacture or even its use. This will depend on the respectivechemistries of the ingredients, their stoichiometry, and thetemperatures encountered in the grease making process or during its use.It will also depend, naturally enough, on whether or not the species areadded as a pre-reacted additive package. For example, the acid aminephosphates may be added as discrete amines and acid phosphates but thesemay react to form a new entity in the final grease composition under theprocessing conditions used in the grease manufacture.

Viscosity Improver(s) or Modifier(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one viscosity improver or modifier(e.g., 1, 2, 3, 4, 5, 6, or more viscosity improver or modifier). Theviscosity improver, viscosity modifier, or Viscosity Index (VI) modifierincreases the viscosity of the composition of the present disclosure atelevated temperatures, thereby increasing film thickness, and havinglimited effects on the viscosity of the composition of the presentdisclosure at low temperatures. In certain embodiments, the compositionof the present disclosure comprises at least one viscosity improver(e.g., 1, 2, 3, 4, 5, 6, or more viscosity improver(s)). Any viscosityimprover that is known or that becomes known in the art may be utilizedin the composition of the present disclosure. Exemplary viscosityimprovers include high molecular weight hydrocarbons, polyesters andviscosity index improver dispersants that function as both a viscosityindex improver and a dispersant. The molecular weight of these polymerscan range from about 1,000 to about 1,500,000 (e.g., about 20,000 toabout 1,200,000 or about 50,000 to about 1,000,000). In a particularembodiment, the molecular weights of these polymers can range from about1,000 to about 1,000,000 (e.g., about 1,200 to about 500,000 or about1,200 to about 5,000).

In certain embodiments, the viscosity improver is at least one of linearor star-shaped polymers of methacrylate, linear or star-shapedcopolymers of methacrylate, butadiene, olefins, alkylated styrenes,polyisobutylene, polymethacrylate (e.g., copolymers of various chainlength alkyl methacrylates), copolymers of ethylene and propylene,hydrogenated block copolymers of styrene and isoprene, or combinationsthereof. For example, the viscosity improver may includestyrene-isoprene or styrene-butadiene based polymers of about 50,000 toabout 200,000 molecular weight.

Olefin copolymers are commercially available from Chevron OroniteCompany LLC under the trade designation “PARATONE®” (such as “PARATONE®8921” and “PARATONE® 8941”); from Afton Chemical Corporation under thetrade designation “HiTEC®” (such as “HiTEC® 5850B”); and from TheLubrizol Corporation under the trade designation “Lubrizol® 7067C”.Hydrogenated polyisoprene star polymers are commercially available fromInfineum International Limited, e.g., under the trade designation“SV200” and “SV600”. Hydrogenated diene-styrene block copolymers arecommercially available from Infineum International Limited, e.g., underthe trade designation “SV 50”.

The polymethacrylate or polyacrylate polymers can be linear polymerswhich are available from Evnoik Industries under the trade designation“Viscoplex®” (e.g., Viscoplex 6-954) or star polymers which areavailable from Lubrizol Corporation under the trade designation Asteric™(e.g., Lubrizol 87708 and Lubrizol 87725).

Illustrative vinyl aromatic-containing polymers useful in the presentdisclosure may be derived predominantly from vinyl aromatic hydrocarbonmonomer. Illustrative vinyl aromatic-containing copolymers useful in thepresent disclosure may be represented by the following formula:

A-B,

wherein:A is a polymeric block derived predominantly from vinyl aromatichydrocarbon monomer, andB is a polymeric block derived predominantly from conjugated dienemonomer.

Although their presence is not required to obtain the benefit of thecomposition of the present disclosure, viscosity modifiers may be usedin an amount of less than about 10 weight percent (e.g. less than about7 weight percent or less than about 4 weight percent). In certainembodiments, the viscosity improver is present in an amount less than 2weight percent, less than about 1 weight percent, or less than about 0.5weight percent, based on the total weight of the composition of thepresent disclosure. Viscosity modifiers are generally added asconcentrates, in large amounts of diluent oil.

As used herein, the viscosity modifier concentrations are given on an“as delivered” basis. The active polymer may be delivered with a diluentoil. The “as delivered” viscosity modifier may contain from about 20weight percent to about 75 weight percent of an active polymer forpolymethacrylate or polyacrylate polymers, or from about 8 weightpercent to about 20 weight percent of an active polymer for olefincopolymers, hydrogenated polyisoprene star polymers, or hydrogenateddiene-styrene block copolymers, in the “as delivered” polymerconcentrate.

Antioxidant(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one antioxidant (e.g., 1, 2, 3, 4,5, 6, or more antioxidant(s)). The antioxidant(s) may be added to retardthe oxidative degradation of the composition in storage or duringservice. Such degradation may result in deposits on metal surfaces, thepresence of sludge, or a viscosity increase in the lubricant. Oneskilled in the art knows a wide variety of oxidation inhibitors that areuseful in lubricating oil compositions. See, Klamann in Lubricants andRelated Products, op cite, and U.S. Pat. Nos. 4,798,684 and 5,084,197,for example. Any antioxidant that is known or that becomes known in theart may be utilized in the composition of the present disclosure.

Two general types of oxidation inhibitors are those that react with theinitiators, peroxy radicals, and hydroperoxides to form inactivecompounds, and those that decompose these materials to form less activecompounds. Examples are hindered (alkylated) phenols, e.g.6-di(tert-butyl)-4-methylphenol [2,6-di(tert-butyl)-p-cresol, DBPC], andaromatic amines, e.g. N-phenyI-α-naphthalamine. These oxidationinhibitors are used in turbine, circulation, and hydraulic oils that areintended for extended service.

The antioxidant or antioxidants may be present in an amount equal to orless than about 6 wt. %, equal to or less than about 5.75 wt. %, equalto or less than about 5.5 wt. %, equal to or less than about 5.25 wt. %,equal to or less than about 5 wt. %, equal to or less than about 4.75wt. %, equal to or less than about 4.5 wt. %, equal to or less thanabout 4.25 wt. %, equal to or less than about 4 wt. %, equal to or lessthan about 3.75 wt. %, equal to or less than about 3.5 wt. %, equal toor less than about 3.25 wt. %, equal to or less than about 3 wt. %,equal to or less than about 2.75 wt. %, equal to or less than about 2.5wt. %, equal to or less than about 2.25 wt. %, equal to or less thanabout 2 wt. %, equal to or less than about 1.75 wt. %, equal to or lessthan about 1.5 wt. %, equal to or less than about 1.25 wt. %, equal toor less than about 1 wt. %, equal to or less than about 0.75 wt. %,equal to or less than about 0.50 wt. %, or equal to or less than about0.25 wt. % on an as-received basis. For example, the antioxidant orantioxidants may be present in an amount of about 0.1 wt. % to about 6wt. %, about 0.1 wt. % to about 5 wt. %, about 0.1 wt. % to about 4 wt.%, about 0.1 wt. % to about 3 wt. %, about 0.1 wt. % to about 2 wt. %,about 0.1 wt. % to about 1.5 wt. %, about 0.1 wt. % to about 1 wt. %,about 0.1 wt. % to about 0.75 wt. %, about 0.1 wt. % to about 0.5 wt. %,about 0.2 wt. % to about 6 wt. %, about 0.2 wt. % to about 5 wt. %,about 0.2 wt. % to about 4 wt. %, about 0.2 wt. % to about 3 wt. %,about 0.2 wt. % to about 2 wt. %, about 0.2 wt. % to about 1.5 wt. %,about 0.2 wt. % to about 1 wt. %, about 0.2 wt. % to about 0.75 wt. %,about 0.2 wt. % to about 0.5 wt. %, about 0.3 wt. % to about 6 wt. %,about 0.3 wt. % to about 5 wt. %, about 0.3 wt. % to about 4 wt. %,about 0.3 wt. % to about 3 wt. %, about 0.3 wt. % to about 2 wt. %,about 0.3 wt. % to about 1.5 wt. %, about 0.3 wt. % to about 1 wt. %,about 0.3 wt. % to about 0.75 wt. %, about 0.3 wt. % to about 0.5 wt. %,about 0.5 wt. % to about 6 wt. %, about 0.5 wt. % to about 5 wt. %,about 0.5 wt. % to about 4 wt. %, about 0.5 wt. % to about 3 wt. %,about 0.5 wt. % to about 2 wt. % about 0.5 wt. % to about 1.5 wt. %,about 0.5 wt. % to about 1 wt. %, about 0.5 wt. % to about 0.75 wt. %,about 0.5 wt. % to about 0.5 wt. %, about 1 wt. % to about 6 wt. %,about 1 wt. % to about 5 wt. %, about 1 wt. % to about 4 wt. %, about 1wt. % to about 3 wt. %, about 2 wt. % to about 6 wt. %, about 2 wt. % toabout 5 wt. %, about 2 wt. % to about 4 wt. %, about 3 wt. % to about 6wt. %, about 3 wt. % to about 5 wt. %, about 4 wt. % to about 6 wt. %,or about 5 wt. % to about 6 wt. % on an as-received basis.

The below discussion of phenolic antioxidants is presented only by wayof example, and is not limiting on the type of phenolic antioxidantsthat can be utilized in the composition of the present disclosure.

Useful antioxidants include hindered phenols. These phenolicantioxidants may be ashless (metal-free) phenolic compounds or neutralor basic metal salts of certain phenolic compounds. In an embodiment,the phenolic antioxidant compounds or compounds are hindered phenolicswhich are the ones which contain a sterically hindered hydroxyl group,such as those that are derivatives of dihydroxy aryl compounds in whichthe hydroxyl groups are in the o- or p-position to each other. Incertain embodiments, the phenolic antioxidant or antioxidants arehindered phenols substituted with C6+ alkyl groups and the alkylenecoupled derivatives of these hindered phenols. Examples of phenolicmaterials of this type 2-t-butyl-4-heptyl phenol; 2-t-butyl-4-octylphenol; 2-t-butyl-4-dodecyl phenol; 2,6-di-t-butyl-4-heptyl phenol;2,6-di-t-butyl-4-dodecyl phenol; 2-methyl-6-t-butyl-4-heptyl phenol; and2-methyl-6-t-butyl-4-dodecyl phenol. Other useful hindered mono-phenolicantioxidants may include for example hindered 2,6-di-alkyl-phenolicproprionic ester derivatives. Bis-phenolic antioxidants may also beadvantageously used in combination with the composition of the presentdisclosure. Examples of ortho-coupled phenols include:2,2′-bis(4-heptyl-6-t-butyl-phenol); 2,2′-bis(4-octyl-6-t-butyl-phenol);and 2,2′-bis(4-dodecyl-6-t-butyl-phenol). Para-coupled bisphenolsinclude for example 4,4′-bis(2,6-di-t-butyl phenol) and4,4′-methylene-bis(2,6-di-t-butyl phenol).

Further examples of phenol-based antioxidants include 2-t-butylphenol,2-t-butyl-4-methylphenol, 2-t-butyl-5-methylphenol,2,4-di-t-butylphenol, 2,4-dimethyl-6-t-butylphenol,2-t-butyl-4-methoxyphenol, 3-t-butyl-4-methoxyphenol,2,5-di-t-butylhydroquinone (manufactured by the Kawaguchi Kagaku Co.under trade designation “Antage DBH”), 2,6-di-t-butylphenol and2,6-di-t-butyl-4-alkylphenols such as 2,6-di-t-butyl-4-methylphenol and2,6-di-t-butyl-4-ethylphenol; 2,6-di-t-butyl-4-alkoxyphenols such as2,6-di-t-butyl-4-methoxyphenol and 2,6-di-t-butyl-4-ethoxyphenol,3,5-di-t-butyl-4-hydroxybenzylmercaptoocty- 1 acetate,alkyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionates such asn-octyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate (manufactured bythe Yoshitomi Seiyaku Co. under the trade designation “Yonox SS”),n-dodecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate and2′-ethylhexyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate;2,6-di-t-butyl-alpha-dimethylamino-p-cresol,2,2′-methylenebis(4-alkyl-6-t-butylphenol) compounds such as2,2′-methylenebis(4-methyl-6-t-butylphenol) (manufactured by theKawaguchi Kagaku Co. under the trade designation “Antage W-400”) and2,2′-methylenebis(4-ethyl-6-t-butylphenol) (manufactured by theKawaguchi Kagaku Co. under the trade designation “Antage W-500”);bisphenols such as 4,4′-butylidenebis(3-methyl-6-t-butyl-phenol)(manufactured by the Kawaguchi Kagaku Co. under the trade designation“Antage W-300”), and 4,4′-methylenebis(2,6-di-t-butylphenol)(manufactured by Laporte Performance Chemicals under the tradedesignation “Ionox 220AH”).

Other examples of phenol-based antioxidants include4,4′-bis(2,6-di-t-butylphenol), 2,2-(di-p-hydroxyphenyl)propane(Bisphenol A), 2,2-bis(3,5-di-t-butyl-4-hydroxyphenyl)propane,4,4′-cyclohexylidenebis(2,6-di-t-butylphenol), hexamethylene glycol bis[3, (3,5-di-t-butyl-4-hydroxyphenyl)propionate] (manufactured by theCiba Specialty Chemicals Co. under the trade designation “IrganoxL109”), triethylene glycolbis[3-(3-t-butyl-4-hydrox-y-5-methylphenyl)propionate] (manufactured bythe Yoshitomi Seiyaku Co. under the trade designation “Tominox 917”),2,2′-thio[diethyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate](manufactured by the Ciba Speciality Chemicals Co. under the tradedesignation “Irganox L115”),3,9-bis{1,1-dimethyl-2-[3-(3-t-butyl-4-hydroxy-5-methylphenyl)-propionylo-xy]ethyl}2,4,8, 10-tetraoxaspiro[5,5]undecane (manufactured by the Sumitomo KagakuCo. under the trade designation “Sumilizer GA80”) and4,4′-thiobis(3-methyl-6-t-butylphenol) (manufactured by the KawaguchiKagaku Co. under the trade designation “Antage RC”),2,2′-thiobis(4,6-di-t-butylresorcinol); polyphenols, such astetrakis[methylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionato]methane(manufactured by the Ciba Speciality Chemicals Co. under the tradedesignation “Irganox L101”),1,1,3-tris(2-methyl-4-hydroxy-5-t-butylphenyl)butane (manufactured bythe Yoshitomi Seiyaku Co. under the trade designation “Yoshinox 930”),1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl)benzene(manufactured by Ciba Speciality Chemicals under the trade designation“Irganox 330”), bis[3,3′-bis(4′-hydroxy-3′-t-butylpheny-l)butyric acid]glycol ester,2-(3′,5′-di-t-butyl-4-hydroxyphenyl)-methyl-4-(2″,4″-di-t-butyl-3″-hydroxyphenyl)methyl-6-t-butylphenoland 2,6-bis(2′-hydroxy-3′-t-butyl-5′-methylbenzyl)-4-methylphenol; andphenol/aldehyde condensates, such as the condensates of p-t-butylphenoland formaldehyde and the condensates of p-t-butylphenol andacetaldehyde.

The phenolic antioxidant or phenolic type antioxidant include sulfurizedand non-sulfurized phenolic antioxidants. Phenolic antioxidants includecompounds having one or more than one hydroxyl group bound to anaromatic ring which may itself be mononuclear (e.g., benzyl) orpoly-nuclear (e.g., naphthyl and spiro aromatic compounds). Thus, phenoltype antioxidants include phenol per se, catechol, resorcinol,hydroquinone, naphthol, etc., as well as alkyl or alkenyl and sulfurizedalkyl or alkenyl derivatives thereof, and bisphenol type compoundsincluding such bi-phenol compounds linked by alkylene bridges sulfuricbridges or oxygen bridges. Alkyl phenols may include mono- andpoly-alkyl or alkenyl phenols, the alkyl or alkenyl group containingfrom about 3 to about 100 carbons (e.g., about 4 to about 50 carbons)and sulfurized derivatives thereof. The number of alkyl or alkenylgroups present in the aromatic ring may range from 1 up to the availableunsatisfied valences of the aromatic ring remaining after counting thenumber of hydroxyl groups bound to the aromatic ring.

For example, the phenolic antioxidant may be represented by thefollowing formula:

(R)_(x)—Ar—(OH)_(y)

wherein:Ar is selected from the group consisting of:

wherein:R is a C₃-C₁₀₀ alkyl or alkenyl group, a sulfur substituted alkyl oralkenyl group (e.g., a C₄-C₅₀ alkyl or alkenyl group or sulfursubstituted alkyl or alkenyl group, a C₃-C₁₀₀ alkyl or sulfursubstituted alkyl group, or a C₄-C₅₀ alkyl group);R^(G) is a C₁-C₁₀₀ alkylene or sulfur substituted alkylene group (e.g.,a C₂-C₅₀ alkylene or sulfur substituted alkylene group or a C₂-C₂alkylene or sulfur substituted alkylene group);y is at least 1 to up to the available valences of Ar;x ranges from 0 to up to the available valances of Ar-y;z ranges from 1 to 10;n ranges from 0 to 20;m is 0 to 4; andp is 0 or 1.

In certain embodiments, at least one of: R is C₄-C₅₀ alkyl group, R^(g)is a C₂-C₂₀ alkylene or sulfur substituted alkylene group, y ranges from1 to 3, x ranges from 0 to 3, z ranges from 1 to 4, n ranges from 0 to5, p is 0, or a combination thereof.

In particular embodiments, the phenolic antioxidant includes hinderedphenolics and phenolic esters that contain a sterically hinderedhydroxyl group. For example, the phenolic antioxidant can includederivatives of dihydroxy aryl compounds in which the hydroxyl groups arein the o- or p-position to each other. The phenolic antioxidant mayinclude the hindered phenols substituted with C₁+ alkyl groups and thealkylene coupled derivatives of these hindered phenols, such as:2-t-butyl-4-heptyl phenol; 2-t-butyl-4-octyl phenol; 2-t-butyl-4-dodecylphenol; 2,6-di-t-butyl-4-heptyl phenol; 2,6-di-t-butyl-4-dodecyl phenol;2-methyl-6-t-butyl-4-heptyl phenol; 2-methyl-6-t-butyl-4-dodecyl phenol;2,6-di-t-butyl-4 methyl phenol; 2,6-di-t-butyl-4-ethyl phenol;2,6-di-t-butyl 4 alkoxy phenol; and/or

In certain embodiments, the phenolic type antioxidant is at least one ofEthanox® 4710, Irganox® 1076, Irganox® L1035, Irganox® 1010, Irganox®L109, Irganox® L118, Irganox® L135, or a combination thereof.

The phenolic antioxidant or antioxidants may be present in an amount ofabout 0.05 wt. % to about 3 wt. %, about 0.05 wt. % to about 2.5 wt. %,about 0.05 wt. % to about 2 wt. %, about 0.05 wt. % to about 1.5 wt. %,about 0.05 wt. % to about 1 wt. %, about 0.05 wt. % to about 0.75 wt. %,about 0.05 wt. % to about 0.5 wt. %, about 0.05 wt. % to about 0.3 wt.%, about 0.1 wt. % to about 3 wt. %, about 0.1 wt. % to about 2.5 wt. %,about 0.1 wt. % to about 2 wt. %, about 0.1 wt. % to about 1.5 wt. %,about 0.1 wt. % to about 1 wt. %, about 0.1 wt. % to about 0.75 wt. %,about 0.1 wt. % to about 0.5 wt. %, about 0.1 wt. % to about 0.3 wt. %,about 0.5 wt. % to about 3 wt. %, about 0.5 wt. % to about 2.5 wt. %,about 0.5 wt. % to about 2 wt. %, about 0.5 wt. % to about 1.5 wt. %,about 0.5 wt. % to about 1 wt. %, about 1 wt. % to about 3 wt. %, about1 wt. % to about 2.5 wt. %, about 1 wt. % to about 2 wt. %, about 1 wt.% to about 1.75 wt. %, about 1 wt. % to about 1.5 wt. %, about 1.5 wt. %to about 3 wt. %, about 1.5 wt. % to about 2.5 wt. %, about 1.5 wt. % toabout 2 wt. %, about 2 wt. % to about 3 wt. %, about 2 wt. % to about2.5 wt. %, or about 2.5 wt. % to about 3 wt. %, on an as-received basis.

Effective amounts of one or more catalytic antioxidants may be used. Thecatalytic antioxidants comprise an effective amount of a) one or moreoil soluble polymetal organic compounds; and, effective amounts of b)one or more substituted N,N′-diaryl-o-phenylenediamine compounds or c)one or more hindered phenol compounds; or a combination of both b) andc). Catalytic antioxidants are more fully described in U.S. Pat. No.8,048,833, which is incorporated herein by reference in its entirety.

Non-phenolic oxidation inhibitors that may be used in the composition ofthe present disclosure include aromatic amine antioxidants, which may beused either as such or in combination with phenolic antioxidants.

An exemplary aromatic amine antioxidant includes alkylated andnon-alkylated aromatic amines, such as aromatic monoamines of theformula

R¹R²R³N,

wherein:R¹ is an aliphatic, aromatic or substituted aromatic group;R² is an aromatic or a substituted aromatic group;R³ is H, alkyl, aryl or R⁴S(O)_(X)R⁵;R⁴ is an alkylene, alkenylene, or aralkylene group;R⁵ is a higher alkyl group, or an alkenyl, aryl, or alkaryl group; andx is 0, 1 or 2.

The aliphatic group R¹ may contain from 1 to about 20 carbon atoms (e.g.from about 6 to 12 carbon atoms). The aliphatic group may be a saturatedaliphatic group. In certain embodiments, both R¹ and R² are aromatic orsubstituted aromatic groups, and the aromatic group may be a fused ringaromatic group such as naphthyl. Aromatic groups R¹ and R² may be joinedtogether with other groups such as S.

The aminic antioxidant may be an aromatic amine antioxidant, such as aphenyl-α-naphthyl amine (e.g., Irganox® L06) which is described by thefollowing chemical structure:

wherein:R^(z) is hydrogen or a C₁ to C₁₄ linear or C₃ to C₁₄ branched alkylgroup; andn is an integer ranging from 1 to 5 (e.g. 1).

In certain embodiments, at least one of: R^(z) is C₁ to C₁₀ linear or C₃to C₁₀ branched alkyl group; n is 1; or a combination thereof.

In another embodiment, R^(z) is a linear or branched C₆ to C₈.

In certain embodiments, the aromatic amine antioxidant can have at least6 carbon atoms substituted with an alkyl groups. Examples of aliphaticgroups include hexyl, heptyl, octyl, nonyl, and decyl. In anembodiments, the aliphatic groups will not contain more than about 14carbon atoms. Additional amine antioxidants include diphenylamines,phenyl naphthylamines, phenothiazines, imidodibenzyls, and diphenylphenylene diamines. In a particular embodiment, a mixture of two or more(e.g., 2, 3, 4, 5, or more) aromatic amine antioxidants are present inthe composition of the present disclosure. Polymeric amine antioxidantscan also be used. Particular examples of aromatic amine antioxidantsuseful in the composition of the present disclosure include:p,p′-dioctyldiphenylamine; t-octylphenyl-alpha-naphthylamine;phenyl-alphanaphthylamine; and p-octylphenyl-alpha-naphthylamine.

Further examples of amine-based antioxidants includedialkyldiphenylamines, such as p,p′-dioctyldiphenylamine (manufacturedby the Seiko Kagaku Co. under the trade designation “Nonflex OD-3”),p,p′-di-alpha-methylbenzyl-diphenylamine andN-p-butylphenyl-N-p′-octylphenylamine; monoalkyldiphenylamines, such asmono-t-butyldiphenylamine, and monooctyldiphenylamine;bis(dialkylphenyl)amines such as di(2,4-diethylphenyl)amine anddi(2-ethyl-4-nonylphenyl)amine; alkylphenyl-1-naphthylamines, such asoctylphenyl-1-naphthylamine and N-t-dodecylphenyl-1-naphthylamine;arylnaphthylamines, such as 1-naphthylamine, phenyl-1-naphthylamine,phenyl-2-naphthylamine, N-hexylphenyl-2-naphthylamine andN-octylphenyl-2-naphthylamine, phenylenediamines such asN,N′-diisopropyl-p-phenylenediamine andN,N′-diphenyl-p-phenylenediamine, and phenothiazines such asphenothiazine (manufactured by the Hodogaya Kagaku Co.: Phenothiazine)and 3,7-dioctylphenothiazine.

A sulfur-containing antioxidant may be any and every antioxidantcontaining sulfur, for example, including dialkyl thiodipropionates suchas dilauryl thiodipropionate and distearyl thiodipropionate,dialkyldithiocarbamic acid derivatives (excluding metal salts),bis(3,5-di-t-butyl-4-hydroxybenzyl)sulfide, mercaptobenzothiazole,reaction products of phosphorus pentoxide and olefins, and dicetylsulfide. For example, the sulfur-containing antioxidant is a dialkylthiodipropionate, such as dilauryl thiodipropionate and distearylthiodipropionate.

Additional examples of sulphur-based antioxidants includedialkylsulphides, such as didodecylsulphide and dioctadecylsulphide;thiodipropionic acid esters, such as didodecyl thiodipropionate,dioctadecyl thiodipropionate, dimyristyl thiodipropionate anddodecyloctadecyl thiodipropionate, and 2-mercaptobenzimidazole. In anembodiment, the antioxidant is a sulfurized alkyl phenols, or an alkalior alkaline earth metal salt thereof.

In certain embodiments, the composition of the present disclosureincludes at least one aminic antioxidant (e.g., 1, 2, 3, 4, 5, or more)present in an amount equal to or less than about 6 wt. %, equal to orless than about 5.75 wt. %, equal to or less than about 5.5 wt. %, equalto or less than about 5.25 wt. %, equal to or less than about 5 wt. %,equal to or less than about 4.75 wt. %, equal to or less than about 4.5wt. %, equal to or less than about 4.25 wt. %, equal to or less thanabout 4 wt. %, equal to or less than about 3.75 wt. %, equal to or lessthan about 3.5 wt. %, equal to or less than about 3.25 wt. %, equal toor less than about 3 wt. %, equal to or less than about 2.75 wt. %,equal to or less than about 2.5 wt. %, equal to or less than about 2.25wt. %, equal to or less than about 2 wt. %, equal to or less than about1.75 wt. %, equal to or less than about 1.5 wt. %, equal to or less thanabout 1.25 wt. %, equal to or less than about 1 wt. %, equal to or lessthan about 0.75 wt. %, equal to or less than about 0.50 wt. %, or equalto or less than about 0.25 wt. % on an as-received basis. For example,the aminic antioxidant or antioxidants may be present in an amount ofabout 0.1 wt. % to about 6 wt. %, about 0.1 wt. % to about 5 wt. %,about 0.1 wt. % to about 4 wt. %, about 0.1 wt. % to about 3 wt. %,about 0.1 wt. % to about 2 wt. %, about 0.1 wt. % to about 1.5 wt. %,about 0.1 wt. % to about 1 wt. %, about 0.1 wt. % to about 0.75 wt. %,about 0.1 wt. % to about 0.5 wt. %, about 0.2 wt. % to about 6 wt. %,about 0.2 wt. % to about 5 wt. %, about 0.2 wt. % to about 4 wt. %,about 0.2 wt. % to about 3 wt. %, about 0.2 wt. % to about 2 wt. %,about 0.2 wt. % to about 1.5 wt. %, about 0.2 wt. % to about 1 wt. %,about 0.2 wt. % to about 0.75 wt. %, about 0.2 wt. % to about 0.5 wt. %,about 0.3 wt. % to about 6 wt. %, about 0.3 wt. % to about 5 wt. %,about 0.3 wt. % to about 4 wt. %, about 0.3 wt. % to about 3 wt. %,about 0.3 wt. % to about 2 wt. %, about 0.3 wt. % to about 1.5 wt. %,about 0.3 wt. % to about 1 wt. %, about 0.3 wt. % to about 0.75 wt. %,about 0.3 wt. % to about 0.5 wt. %, about 0.5 wt. % to about 6 wt. %,about 0.5 wt. % to about 5 wt. %, about 0.5 wt. % to about 4 wt. %,about 0.5 wt. % to about 3 wt. %, about 0.5 wt. % to about 2 wt. %,about 0.5 wt. % to about 1.5 wt. %, about 0.5 wt. % to about 1 wt. %,about 0.5 wt. % to about 0.75 wt. %, about 0.5 wt. % to about 0.5 wt. %,about 1 wt. % to about 6 wt. %, about 1 wt. % to about 5 wt. %, about 1wt. % to about 4 wt. %, about 1 wt. % to about 3 wt. %, about 2 wt. % toabout 6 wt. %, about 2 wt. % to about 5 wt. %, about 2 wt. % to about 4wt. %, about 3 wt. % to about 6 wt. %, about 3 wt. % to about 5 wt. %,about 4 wt. % to about 6 wt. %, or about 5 wt. % to about 6 wt. % on anas-received basis.

Other oxidation inhibitors that have proven useful in compositions ofthe present disclosure are chlorinated aliphatic hydrocarbons such aschlorinated wax; organic sulfides and polysulfides such as benzyldisulfide, bis(chlorobenzyl)disulfide, dibutyl tetrasulfide, sulfurizedmethyl ester of oleic acid, sulfurized alkylphenol, sulfurizeddipentene, and sulfurized terpene; phosphosulfurized hydrocarbons suchas the reaction product of a phosphorus sulfide with turpentine ormethyl oleate, phosphorus esters including principally dihydrocarbon andtrihydrocarbon phosphites such as dibutyl phosphite, diheptyl phosphite,dicyclohexyl phosphite, pentylphenyl phosphite, dipentylphenylphosphite, tridecyl phosphite, distearyl phosphite, dimethyl naphthylphosphite, oleyl 4-pentylphenyl phosphite, polypropylene (molecularweight 500)-substituted phenyl phosphite, diisobutyl-substituted phenylphosphite; metal thiocarbamates, such as zinc dioctyldithiocarbamate,and barium heptylphenyl dithiocarbamate; Group II metalphosphorodithioates such as zinc dicyclohexylphosphorodithioate, zincdioctylphosphorodithioate, barium di(heptylphenyl)(phosphorodithioate,cadmium dinonylphosphorodithioate, and the reaction of phosphoruspentasulfide with an equimolar mixture of isopropyl alcohol,4-methyl-2-pentanol, and n-hexyl alcohol.

Another class of antioxidants which may be used in the lubricating oilcompositions disclosed herein are oil soluble copper compounds. Any oilsoluble suitable copper compound may be blended into the composition ofthe present disclosure. Examples of suitable copper antioxidants includecopper dihydrocarbyl thio- or dithio-phosphates and copper salts ofcarboxylic acid (naturally occurring or synthetic). Other suitablecopper salts include copper dithiacarbamates, sulphonates, phenates, andacetylacetonates. Basic, neutral, or acidic copper Cu(I) and or Cu(II)salts derived from alkenyl succinic acids or anhydrides are known to beparticularly useful.

In an embodiment, the antioxidant includes hindered phenols, arylamines,or a combination thereof. These antioxidants may be used individually bytype or in combination with one another.

Pour Point Depressant(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one (e.g., 1, 2, 3, 4, 5, or 6, ormore) pour point depressant or a lube oil flow improver. Pour pointdepressant may be added to lower the minimum temperature at which thefluid will flow or can be poured. Any pour point depressant or lube oilflow improved that is known or that becomes known in the art may beutilized in the composition of the present disclosure. In certainembodiments, the pour point depressant includes at least one (e.g., 1,2, 3, or 4 or more) pour point depressant or lube oil flow improver,such as at least one of alkylated naphthalenes polymethacrylates (e.g.,copolymers of various chain length alkyl methacrylates), polyacrylates,polyarylamides, condensation products of haloparaffin waxes and aromaticcompounds, vinyl carboxylate polymers, terpolymers of dialkylfumarates,vinyl esters of fatty acids, allyl vinyl ethers, or combinationsthereof. U.S. Pat. Nos. 1,815,022; 2,015,748; 2,191,498; 2,387,501;2,655, 479; 2,666,746; 2,721,877; 2,721,878; and 3,250,715 describeuseful pour point depressants and/or the preparation thereof.

The pour point depressant or depressants may be present in an amountequal to or less than about 5 wt. %, for example about 0.01 to about 1.5wt. %. For example, the pour point depressant or depressants may bepresent in an amount equal to or less than about 5 wt. %, equal to orless than about 4.75 wt. %, equal to or less than about 4.5 wt. %, equalto or less than about 4.25 wt. %, equal to or less than about 4 wt. %,equal to or less than about 3.75 wt. %, equal to or less than about 3.5wt. %, equal to or less than about 3.25 wt. %, equal to or less thanabout 3 wt. %, equal to or less than about 2.75 wt. %, equal to or lessthan about 2.5 wt. %, equal to or less than about 2.25 wt. %, equal toor less than about 2 wt. %, equal to or less than about 1.75 wt. %,equal to or less than about 1.5 wt. %, equal to or less than about 1.25wt. %, equal to or less than about 1 wt. %, equal to or less than about0.75 wt. %, equal to or less than about 0.50 wt. %, or equal to or lessthan about 0.25 wt. % of the composition of the present disclosure. Forexample, the pour point depressant or depressants may be present in anamount of about 0.1 wt. % to about 5 wt. %, about 0.1 wt. % to about 4wt. %, about 0.1 wt. % to about 3 wt. %, about 0.1 wt. % to about 2 wt.%, about 0.1 wt. % to about 1.5 wt. %, about 0.1 wt. % to about 1 wt. %,about 0.1 wt. % to about 0.75 wt. %, about 0.1 wt. % to about 0.5 wt. %,about 0.2 wt. % to about 5 wt. %, about 0.2 wt. % to about 4 wt. %,about 0.2 wt. % to about 3 wt. %, about 0.2 wt. % to about 2 wt. %,about 0.2 wt. % to about 1.5 wt. %, about 0.2 wt. % to about 1 wt. %,about 0.2 wt. % to about 0.75 wt. %, about 0.2 wt. % to about 0.5 wt. %,about 0.3 wt. % to about 5 wt. %, about 0.3 wt. % to about 4 wt. %,about 0.3 wt. % to about 3 wt. %, about 0.3 wt. % to about 2 wt. %,about 0.3 wt. % to about 1.5 wt. %, about 0.3 wt. % to about 1 wt. %,about 0.3 wt. % to about 0.75 wt. %, about 0.3 wt. % to about 0.5 wt. %,about 0.5 wt. % to about 5 wt. %, about 0.5 wt. % to about 4 wt. %,about 0.5 wt. % to about 3 wt. %, about 0.5 wt. % to about 2 wt. %,about 0.5 wt. % to about 1.5 wt. %, about 0.5 wt. % to about 1 wt. %,about 0.5 wt. % to about 0.75 wt. %, about 0.5 wt. % to about 0.5 wt. %,about 1 wt. % to about 5 wt. %, about 1 wt. % to about 4 wt. %, about 1wt. % to about 3 wt. %, about 2 wt. % to about 5 wt. %, about 2 wt. % toabout 4 wt. %, or about 3 wt. % to about 5 wt. % of the composition ofthe present disclosure.

Seal Compatibility Agent(s)

In other embodiments, the composition comprises of the presentdisclosure at least one (e.g., 1, 2, 3, 4, or more) seal compatibilityagent. The seal compatibility agent(s) may be added to help swellelastomeric seals by causing a chemical reaction in the fluid orphysical change in the elastomer. Any seal compatibility agent that isknown or that becomes know may be utilized in the composition of thepresent disclosure. For example, the seal compatibility agent or agentsmay include at least one of organic phosphates, aromatic esters,aromatic hydrocarbons, esters (e.g. butylbenzyl phthalate), polybutenylsuccinic anhydride, or sulfolane-type seal swell agents (e.g. Lubrizol730-type seal swell additives), or combinations thereof. Although theirpresence is not required to obtain the benefit of the presentdisclosure, seal compatibility additives may be present in an amount ofzero to about 3 weight percent (e.g., about 0.01 to about 2 weightpercent) of the composition of the present disclosure.

Demulsifier(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one (e.g., 1, 2, 3, or 4, or more)demulsifier. The demulsifier may be added to separate emulsions (e.g.,water-in-oil). Any demulsifier that is known or that becomes know may beutilized in the composition of the present disclosure. An illustrativedemulsifying component is described in EP-A-330,522. This exemplarydemulsifying agent is obtained by reacting an alkylene oxide with anadduct obtained by reaction of a bis-epoxide with a polyhydric alcohol.Demulsifiers are commercially available and may be used in conventionalminor amounts along with other additives such as antifoam agents.Although their presence is not required to obtain the benefit of thepresent disclosure, the emulsifier or emulsifiers may be present acombined amount less than 1 weight percent (e.g. less than 0.1 weightpercent).

In certain embodiments, the demulsifying agent includes at least one ofalkoxylated phenols, phenol-formaldehyde resins, synthetic alkylarylsulfonates (such as metallic dinonylnaphthalene sulfonates), or acombination thereof. In an embodiment, a demulsifing agent is apredominant amount of a water-soluble polyoxyalkylene glycol having apre-selected molecular weight of any value in the range of between about450 and about 5000 or more. In an embodiment, the water solublepolyoxyalkylene glycol demulsifier may also be one produced fromalkoxylation of n-butanol with a mixture of alkylene oxides to form arandom alkoxylated product.

Polyoxyalkylene glycols useful in the present disclosure may be producedby a well-known process for preparing polyalkylene oxide having hydroxylend-groups by subjecting an alcohol or a glycol ether and one or morealkylene oxide monomers, such as ethylene oxide, butylene oxide, orpropylene oxide, to form block copolymers in addition polymerization,while employing a strong base, such as potassium hydroxide as acatalyst. In such a process, the polymerization is commonly carried outunder a catalytic concentration of about 0.3 to about 1.0% by mole ofpotassium hydroxide to the monomer(s) and at high temperature of about100° C. to about 160° C. It is well known that the catalyst potassiumhydroxide is, for the most part, bonded to the chain-end of the producedpolyalkylene oxide in a form of alkoxide in the polymer solution soobtained.

The soluble polyoxyalkylene glycol emulsifier(s) useful in thecompositions of the present disclosure may also be one produced fromalkoxylation of n-butanol with a mixture of alkylene oxides to form arandom alkoxylated product.

Corrosion Inhibitor or Anti-Rust Additive

In any aspect or embodiment, the composition of the present disclosurecomprises at least one (e.g. 1, 2, 3, 4, or more) corrosion inhibitor oranti-rust additive. The corrosion inhibitor or anti-rust additive may beadded to protect lubricated metal surfaces against chemical attack bywater or other contaminants. A wide variety of corrosion inhibitors arecommercially available, and any corrosion inhibitor or anti-rustadditive that is known or that becomes know may be utilized in thecomposition of the present disclosure. In an embodiment, the corrosioninhibitor can be a polar compound that wets the metal surface protectingit with a film of oil. In another embodiment, the anti-rust additive mayabsorb water by incorporating it in a water-in-oil emulsion so that onlythe oil touches the surface. In yet a further embodiment, the corrosioninhibitor chemically adheres to the metal to produce a non-reactivesurface. In certain embodiments, the anti-rust additive or corrosioninhibitor includes at least one zinc dithiophosphates, metal phenolates,basic metal sulfonates, a fatty acid, a fatty acid mixture, amines, or acombination thereof.

Antirust additives may include (short-chain) alkenyl succinic acids,partial esters thereof and nitrogen-containing derivatives thereof andsynthetic alkarylsulfonates, such as metal dinonylnaphthalenesulfonates. Antirust agents include, for example, monocarboxylic acidswhich have from 8 to 30 carbon atoms, alkyl or alkenyl succinates orpartial esters thereof, hydroxy-fatty acids, which have from 12 to 30carbon atoms and derivatives thereof, sarcosines which have from 8 to 24carbon atoms and derivatives thereof, amino acids and derivativesthereof, naphthenic acid and derivatives thereof, lanolin fatty acid,mercapto-fatty acids, and/or paraffin oxides.

Examples of monocarboxylic acids (C8-C30), include, for example,caprylic acid, pelargonic acid, decanoic acid, undecanoic acid, lauricacid, myristic acid, palmitic acid, stearic acid, arachic acid, behenicacid, cerotic acid, montanic acid, melissic acid, oleic acid, docosanicacid, erucic acid, eicosenic acid, beef tallow fatty acid, soy beanfatty acid, coconut oil fatty acid, linolic acid, linoleic acid, talloil fatty acid, 12-hydroxystearic acid, laurylsarcosinic acid,myritsylsarcosinic acid, palmitylsarcosinic acid, stearylsarcosinicacid, oleylsarcosinic acid, alkylated (C8-C20) phenoxyacetic acids,lanolin fatty acid, and C8-C24 mercapto-fatty acids.

Examples of polybasic carboxylic acids include, for example, the alkenyl(C10-C100) succinic acids indicated in CAS No. 27859-58-1 and esterderivatives thereof, dimer acid, N-acyl-N-alkyloxyalkyl aspartic acidesters (U.S. Pat. No. 5,275,749).

Examples of the alkylamines that function as antirust additives or asreaction products with the above carboxylates to give amides and thelike are represented by primary amines, such as laurylamine,coconut-amine, n-tridecylamine, myristylamine, n-pentadecylamine,palmitylamine, n-heptadecylamine, stearylamine, n-nonadecylamine,n-eicosylamine, n-heneicosylamine, n-docosylamine, n-tricosylamine,n-pentacosylamine, oleylamine, beef tallow-amine, hydrogenated beeftallow-amine and soy bean-amine. Examples of the secondary aminesinclude dilaurylamine, di-coconut-amine, di-n-tridecylamine,dimyristylamine, di-n-pentadecylamine, dipalmitylamine,di-n-pentadecylamine, distearylamine, di-n-nonadecylamine,di-n-eicosylamine, di-n-heneicosylamine, di-n-docosylamine,di-n-tricosylamine, di-n-pentacosyl-amine, dioleylamine, di-beeftallow-amine, di-hydrogenated beef tallow-amine and di-soy bean-amine.

Examples of the aforementioned N-alkylpolyalkyenediamines include:ethylenediamines, such as laurylethylenediamine, coconutethylenediamine, n-tridecylethylenediamine-myristylethylenediamine,n-pentadecylethylenediamine, palmitylethylenediamine,n-heptadecylethylenediamine, stearylethylenediamine,n-nonadecylethylenediamine, n-eicosylethylenediamine,n-heneicosylethylenediamine, n-docosylethylendiamine,n-tricosylethylenediamine, n-pentacosylethylenediamine,oleylethylenediamine, beef tallow-ethylenediamine, hydrogenated beeftallow-ethylenediamine and soy bean-ethylenediamine; propylenediaminessuch as laurylpropylenediamine, coconut propylenediamine,n-tridecylpropylenediamine, myristylpropylenediamine,n-pentadecylpropylenediamine, palmitylpropylenediamine,n-heptadecylpropylenediamine, stearylpropylenediamine,n-nonadecylpropylenediamine, n-eicosylpropylenediamine,n-heneicosylpropylenediamine, n-docosylpropylendiamine,n-tricosylpropylenediamine, n-pentacosylpropylenediamine, diethylenetriamine (DETA) or triethylene tetramine (TETA), oleylpropylenediamine,beef tallow-propylenediamine, hydrogenated beef tallow-propylenediamineand soy bean-propylenediamine; butylenediamines such aslaurylbutylenediamine, coconut butylenediamine,n-tridecylbutylenediamine-myristylbutylenediamine,n-pentadecylbutylenediamine, stearylbutylenediamine,n-eicosylbutylenediamine, n-heneicosylbutylenediamine,n-docosylbutylendiamine, n-tricosylbutylenediamine,n-pentacosylbutylenediamine, oleylbutylenediamine, beeftallow-butylenediamine, hydrogenated beef tallow-butylenediamine and soybean butylenediamine; and pentylenediamines such aslaurylpentylenediamine, coconut pentylenediamine,myristylpentylenediamine, palmitylpentylenediamine,stearylpentylenediamine, oleyl-pentylenediamine, beeftallow-pentylenediamine, hydrogenated beef tallow-pentylenediamine andsoy bean pentylenediamine.

The corrosion inhibitor or anti-rust additive may be present in anamount equal to or less than about 5 wt. %, for example about 0.01 to 5wt. %, on an as-received basis. For example, the corrosion inhibitor maybe present in an amount equal to or less than 4 wt. %, equal or lessthan 3 wt. %, equal to or less than 2 wt. %, or equal to or less than 1wt. % on an as-received basis. By way of further example, the corrosioninhibitor may be present in an amount of about 0.01 to about 5 wt. %,about 0.01 to about 4 wt. %, about 0.01 to about 3 wt. %, about 0.01 toabout 2 wt. %, about 0.05 to about 5 wt. %, about 0.05 to about 4 wt. %,about 0.05 to about 3 wt. %, about 0.05 to about 2 wt. %, about 0.1 toabout 5 wt. %, about 0.1 to about 4 wt. %, about 0.1 to about 3 wt. %,about 0.1 to about 2 wt. %, about 1 to about 5 wt. %, about 1 to about 4wt. %, about 1 to about 3 wt. %, about 2 to about 5 wt. %, about 2 toabout 4 wt. %, or about 3 to about 5 wt. %, on an as-received basis.

Metal Passivator(s), Deactivator(s) and Corrosion Inhibitor(s)

In any aspect or embodiment, the composition of the present disclosurecomprises at least one (e.g. 1, 2, 3, 4, 5, or 6, or more) metalpassivator, deactivator, or corrosion inhibitor. This type of componentincludes 2,5-dimercapto-1,3,4-thiadiazoles and derivatives thereof,mercaptobenzothiazoles, alkyltriazoles and benzotriazoles. Examples ofdibasic acids useful as anti-corrosion agents, other than sebacic acids,which may be used in the present disclosure, are adipic acid, azelaicacid, dodecanedioic acid, 3-methyladipic acid, 3-nitrophthalic acid,1,10-decanedicarboxylic acid, and fumaric acid. The anti-corrosioncombination is a straight or branch-chained, saturated or unsaturatedmonocarboxylic acid or ester thereof which may optionally be sulphurizedin an amount up to 35% by weight. In an embodiment, the acid is a C4 toC22 straight chain unsaturated monocarboxylic acid. The monocarboxylicacid may be a sulphurized oleic acid. However, other suitable materialsare oleic acid itself, valeric acid and erucic acid. A component of theanti-corrosion combination is a triazole as previously defined. In anembodiment, the triazole is tolylotriazole, which may be included in thecompositions of the disclosure include triazoles, thiazoles and certaindiamine compounds which are useful as metal deactivators or metalpassivators. Examples include triazole, benzotriazole and substitutedbenzotriazoles, such as alkyl substituted derivatives. The alkylsubstituent may contain up to 1.5 carbon atoms, e.g. up to 8 carbonatoms. The triazoles may contain other substituents on the aromatic ringsuch as halogens, nitro, amino, mercapto, etc. Examples of suitablecompounds are benzotriazole and the tolyltriazoles, ethylbenzotriazoles,hexylbenzotriazoles, octylbenzotriazoles, chlorobenzotriazoles andnitrobenzotriazoles. In a particular embodiment, the compound isbenzotriazole and/or tolyltriazole.

Illustrative substituents include, for example, alkyl that is straightor branched chain, for example, methyl, ethyl, n-propyl, iso-propyl,n-butyl, sec-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, 2-ethylhexyl,n-nonyl, n-decyl, n-dodecyl, n-tetradecyl, n-hexadecyl, n-octadecyl orn-eicosyl; alkenyl that is straight or branched chain, for example,prop-2-enyl, but-2-enyl, 2-methyl-prop-2-enyl, pent-2-enyl,hexa-2,4-dienyl, dec-10-enyl or eicos-2-enyl; cycloalkyl that is, forexample, cyclopentyl, cyclohexyl, cyclooctyl, cyclodecyl, adamantyl orcyclododecyl; aralkyl that is, for example, benzyl, 2-phenylethyl,benzhydryl or naphthylmethyl; aryl that is, for example, phenyl ornaphthyl; heterocyclic group that is, for example, a morpholine,pyrrolidine, piperidine or a perhydroazepine ring; alkylene moietiesthat include, for example, methylene, ethylene, 1:2- or 1:3-propylene,1:4-butylene, 1:6-hexylene, 1:8-octylene, 1:10-decylene and1:12-dodecylene.

Illustrative arylene moieties include, for example, phenylene andnaphthylene. 1-(or 4)-(dimethylaminomethyl) triazole, 1-(or4)-(diethylaminomethyl) triazole, 1-(or 4)-(di-isopropylaminomethyl)triazole, 1-(or 4)-(di-n-butylaminomethyl) triazole, 1-(or4)-(di-n-hexylaminomethyl) triazole, 1-(or 4)-(di-isooctylaminomethyl)triazole, 1-(or 4)-(di-(2-ethylhexyl)aminomethyl) triazole, 1-(or4)-(di-n-decylaminomethyl) triazole, 1-(or 4)-(di-n-dodecylaminomethyl)triazole, 1-(or 4)-(di-n-octadecylaminomethyl) triazole, 1-(or4)-(di-n-eicosylaminomethyl) triazole, 1-(or4)-[di-(prop-2′-enyl)aminomethyl] triazole, 1-(or4)-[di-(but-2′-enyl)aminomethyl] triazole, 1-(or4)-[di-(eicos-2′-enyl)aminomethyl] triazole, 1-(or4)-(di-cyclohexylaminomethyl) triazole, 1-(or 4)-(di-benzylaminomethyl)triazole, 1-(or 4)-(di-phenylaminomethyl) triazole, 1-(or4)-(4′-morpholinomethyl) triazole, 1-(or 4)-(1′-pyrrolidinomethyl)triazole, 1-(or 4)-(1′-piperidinomethyl) triazole, 1-(or4)-(1′-perhydoroazepinomethyl) triazole, 1-(or4)-(2′,2″-dihydroxyethy)aminomethyl] triazole, 1-(or4)-(dibutoxypropyl-aminomethyl) triazole, 1-(or4)-(dibutylthiopropyl-aminomethyl) triazole, 1-(or4)-(di-butylaminopropyl-aminomethyl) triazole,1-(or-4)-(1-methanomine)-N,N-bis(2-ethylhexyl)-methyl benzotriazole,N,N-bis-(1- or 4-triazolylmethyl) laurylamine, N,N-bis-(1- or4-triazolylmethyl) oleylamine, N,N-bis-(1- or 4-triazolylmethyl)ethanolamine and N,N,N′,N′-tetra(1- or 4-triazolylmethyl) ethylenediamine.

The metal deactivating agents which can be used in the composition ofthe present disclosure includes, for example, benzotriazole and the4-alkylbenzotriazoles such as 4-methylbenzotriazole and4-ethylbenzotriazole; 5-alkylbenzotriazoles such as5-methylbenzotriazole, 5-ethylbenzotriazole; 1-alkylbenzotriazoles suchas 1-dioctylauainomethyl-2,3-benzotriazole; benzotriazole derivativessuch as the 1-alkyltolutriazoles, for example,1-dioctylaminomethyl-2,3-t-olutriazole; benzimidazole and benzimidazolederivatives such as 2-(alkyldithio)-benzimidazoles, for example, such as2-(octyldithio)-benzimidazole, 2-(decyldithio)benzimidazole and2-(dodecyldithio)-benzimidazole; 2-(alkyldithio)-toluimidazoles such as2-(octyldithio)-toluimidazole, 2-(decyldithio)-toluimidazole and2-(dodecyldithio)-toluimidazole; indazole and indazole derivatives oftoluimidazoles such as 4-alkylindazole, 5-alkylindazole; benzothiazole,2-mercaptobenzothiazole derivatives (manufactured by the Chiyoda KagakuCo. under the trade designation “Thiolite B-3100”) and2-(alkyldithio)benzothiazoles such as 2-(hexyldithio)benzothiazole and2-(octyldithio)benzothiazole; 2-(alkyl-dithio)toluthiazoles such as2-(benzyldithio)toluthiazole and 2-(octyldithio)toluthiazole,2-(N,N-dialkyldithiocarbamyl)benzothiazoles such as2-(N,N-diethyldithiocarbamyl)benzothiazole,2-(N,N-dibutyldithiocarbamyl)-benzotriazole and2-N,N-dihexyl-dithiocarbamyl)benzotriazole; benzothiazole derivatives of2-(N,N-dialkyldithiocarbamyl)toluthiazoles such as2-(N,N-diethyldithiocarbamyl)toluthiazole,2-(N,N-dibutyldithiocarbamyl)toluthiazole,2-(N,N-dihexyl-dithiocarbamyl)-toluthiazole; 2-(alkyldithio)benzoxazolessuch as 2-(octyldithio)benzoxazo-le, 2-(decyldithio)-benzoxazole and2-(dodecyldithio)benzoxazole; benzoxazole derivatives of2-(alkyldithio)toluoxazoles such as 2-(octyldithio)toluoxazole,2-(decyldithio)toluoxazole, 2-(dodecyldithio)toluoxazole;2,5-bis(alkyldithio)-1,3,4-thiadiazoles such as2,5-bis(heptyldithio)-1,3,4-thiadiazole,2,5-bis-(nonyldithio)-1,-3,4-thiadiazole,2,5-bis(dodecyldithio)-1,3,4-thiadiazole and2,5-bis-(octadecyldithio)-1,3,4-thiadiazole;2,5-bis(N,N-dialkyl-dithioca-rbamyl)-1,3,4-thiadiazoles such as2,5-bis(N,N-diethyldithiocarbamyl)-1,3,-4-thiadiazole,2,5-bis(N,N-dibutyldithiocarbamyl)-1,3,4-thiadiazole and2,5-bis(N,N-dioctyldithiocarbamyl)1,3,4-thiadiazole; thiadiazolederivatives of 2-N,N-dialkyldithiocarbamyl-5-mercapto-1,3,4-thiadiazolessuch as 2-N,N-dibutyldithiocarbamyl-5-mercapto-1,3,4-thiadiazole and2-N,N-dioctyl-dithiocarbamyl-5-mercapto-1,3,4-thiadiazole, and triazolederivatives of 1-alkyl-2,4-triazoles such as1-dioctylaminomethyl-2,4-triazole; or concentrates and/or mixturesthereof.

Although their presence is not required to obtain the benefit of thepresent disclosure, the metal deactivator(s) and corrosion inhibitor(s)may be present from zero to about 1% by weight (e.g. from 0.01% to about0.5% by weight) of the total composition of the present disclosure.

Antiwear Additive(s) or Inhibitor(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one (e.g., 1, 2, 3, 4, 5, or 6, ormore) antiwear additive or wear inhibitor. Any antiwear additive that isknown or that becomes known may be utilized in the lubricating of thepresent disclosure. The antiwear additive may be analkyldithiophosphate(s), aryl phosphate(s) and/or phosphite(s). Theantiwear additive(s) may be essentially free of metals, or they maycontain metal salts.

In certain embodiments, the antiwear additive is a phosphate ester orsalt thereof. A phosphate ester or salt may be a monohydrocarbyl,dihydrocarbyl or a trihydrocarbyl phosphate, wherein each hydrocarbylgroup is saturated. In an embodiment, each hydrocarbyl groupindependently contains from about 8 to about 30, or from about 12 up toabout 28, or from about 14 up to about 24, or from about 14 up to about18 carbons atoms. In an embodiment, the hydrocarbyl groups are alkylgroups. Examples of hydrocarbyl groups include at least one of tridecyl,tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl groups, andmixtures thereof.

A phosphate ester or salt is a phosphorus acid ester prepared byreacting at least one (e.g., 1, 2, 3, 4, or more) phosphorus acid oranhydride with a saturated alcohol. The phosphorus acid or anhydride cambe an inorganic phosphorus reagent, such as phosphorus pentoxide,phosphorus trioxide, phosphorus tetroxide, phosphorous acid, phosphoricacid, phosphorus halide, lower phosphorus esters, or a phosphorussulfide, including phosphorus pentasulfide, and the like. Lowerphosphorus acid esters may contain from 1 to about 7 carbon atoms ineach ester group. Alcohols used to prepare the phosphorus acid esters orsalts. Examples of commercially available alcohols and alcohol mixturesinclude Alfol 1218 (a mixture of synthetic, primary, straight-chainalcohols containing 12 to 18 carbon atoms); Alfol 20+ alcohols (mixturesof C18-C28 primary alcohols having mostly C20 alcohols as determined byGLC (gas-liquid-chromatography)); and Alfol22+ alcohols (C18-C28 primaryalcohols containing primarily C22 alcohols). Alfol alcohols areavailable from, e.g., Continental Oil Company. Another example of acommercially available alcohol mixture is Adol 60 (about 75% by weightof a straight chain C22 primary alcohol, about 15% of a C20 primaryalcohol, and about 8% of C18 and C24 alcohols). The Adol alcohols aremarketed by Ashland Chemical.

The antiwear additive may include at least one (e.g., a mixture of)monohydric fatty alcohol. For example, a mixture of monohydric fattyalcohols derived from naturally occurring triglycerides and ranging inchain length from C8 to C18 may be utilized as an antiwear additive. Avariety of monohydric fatty alcohol mixtures are available from Procter& Gamble Company. These mixtures contain various amounts of fattyalcohols containing 12, 14, 16, or 18 carbon atoms. For example, CO-1214is a fatty alcohol mixture containing 0.5% of C10 alcohol, 66.0% of C12alcohol, 26.0% of C14 alcohol and 6.5% of C16 alcohol.

Another group of commercially available alcohol mixtures include the“Neodol” products available from Shell Chemical Co. For example, Neodol23 is a mixture of C12 and C13 alcohols; Neodol 25 is a mixture of C12to C15 alcohols; and Neodol 45 is a mixture of C14 to C15 linearalcohols. The phosphate contains from about 14 to about 18 carbon atomsin each hydrocarbyl group. The hydrocarbyl groups of the phosphate maybe derived from a mixture of fatty alcohols having from about 14 up toabout 18 carbon atoms. The hydrocarbyl phosphate may also be derivedfrom a fatty vicinal diol. Fatty vicinal diols include, but not limitedto, those available from Ashland Oil under the general trade designationAdol 114 and Adol 158. The former is derived from a straight chain alphaolefin fraction of C11-C14, and the latter is derived from a C15-C18fraction.

Phosphate salts may be prepared by reacting an acidic phosphate esterwith an amine compound or a metallic base to form an amine or a metalsalt. The amines may be monoamines or polyamines. Useful amines includethose amines disclosed in U.S. Pat. No. 4,234,435.

Illustrative monoamines may contain a hydrocarbyl group, which containsfrom 1 to about 30 carbon atoms, or from 1 to about 12, or from 1 toabout 6. Examples of primary monoamines useful in the present disclosureinclude methylamine, ethylamine, propylamine, butylamine,cyclopentylamine, cyclohexylamine, octylamine, dodecylamine, allylamine,cocoamine, stearylamine, and laurylamine. Examples of secondarymonoamines include dimethylamine, diethylamine, dipropylamine,dibutylamine, dicyclopentylamine, dicyclohexylamine, methylbutylamine,ethylhexylamine, etc.

An amine may be a fatty (C8-C30) amine which includes n-octylamine,n-decylamine, n-dodecylamine, n-tetradecylamine, n-hexadecylamine,n-octadecylamine, oleyamine, etc. Also useful fatty amines includecommercially available fatty amines, such as “Armeen” amines (productsavailable from Akzo Chemicals, Chicago, Ill.), e.g. Armeen C, Armeen O,Armeen OL, Armeen T, Armeen HT, Armeen S and Armeen SD, wherein theletter designation relates to the fatty group, such as coco, oleyl,tallow, or stearyl groups.

Other useful amines include primary ether amines, such as thoserepresented by the formula:

R″(OR′)xNH₂,

wherein:R′ is a divalent alkylene group having about 2 to about 6 carbon atoms;x is a number from one to about 150, or from about one to about five, orone; andR″ is a hydrocarbyl group of about 5 to about 150 carbon atoms.

An exemplary or illustrative ether amine is available under the nameSURFAM® amines produced and marketed by Mars Chemical Company, Atlanta,Ga. Additional exemplary ether amines include those identified as SURFAMP14B (decyloxypropylamine), SURFAM P16A (linear C16), and SURFAM P17B(tridecyloxypropylamine). The carbon chain lengths (i.e., C14, etc.) ofthe SURFAM ether amines described above and used hereinafter areapproximate and include the oxygen ether linkage.

A further illustrative amine is a tertiary-aliphatic primary amine. Forexample, the aliphatic group, such as an alkyl group, contains fromabout 4 to about 30, or from about 6 to about 24, or from about 8 toabout 22 carbon atoms. Usually the tertiary alkyl primary amines aremonoamines the alkyl group is a hydrocarbyl group containing from one toabout 27 carbon atoms. Such amines are illustrated by tert-butylamine,tert-hexylamine, 1-methyl-1-amino-cyclohexane, tert-octylamine,tert-decylamine, tert-dodecylamine, tert-tetradecylamine,tert-hexadecylamine, tert-octadecylamine, tert-tetracosanylamine,tert-octacosanylamine, and combinations thereof. Mixtures of tertiaryaliphatic amines may also be used in preparing the phosphate salt.Illustrative of amine mixtures of this type are “Primene 81R”, which isa mixture of C11-C14 tertiary alkyl primary amines, and “Primene JMT”,which is a similar mixture of C18-C22 tertiary alkyl primary amines(both are available from Rohm and Haas Company). The tertiary aliphaticprimary amines and methods for their preparation are known to those ofordinary skill in the art.

Another illustrative amine is a heterocyclic polyamine. The heterocyclicpolyamines include aziridines, azetidines, azolidines, tetra- anddihydropyridines, pyrroles, indoles, piperidines, imidazoles, di- andtetra-hydroimidazoles, piperazines, isoindoles, purines, morpholines,thiomorpholines, N-aminoalkylmorpholines, N-aminoalkylthiomorpholines,N-aminoalkyl-piperazines, N,N′-diaminoalkylpiperazines, azepines,azocines, azonines, azecines and tetra-, di- and perhydro derivatives ofeach of the above, and mixtures of two or more (e.g., 2, 3, 4, 5, 6, ormore) of these heterocyclic amines. In certain embodiments, theheterocyclic amines are saturated 5- and 6-membered heterocyclic aminescontaining only nitrogen, oxygen and/or sulfur in the hetero ring,especially the piperidines, piperazines, thiomorpholines, morpholines,pyrrolidines, and the like. Piperidine, aminoalkyl substitutedpiperidines, piperazine, aminoalkyl substituted piperazines, morpholine,aminoalkyl substituted morpholines, pyrrolidine, andaminoalkyl-substituted pyrrolidines, are especially preferred. Usuallythe aminoalkyl substituents are substituted on a nitrogen atom formingpart of the hetero ring. Specific examples of such heterocyclic aminesinclude N-aminopropylmorpholine, N-aminoethylpiperazine, andN,N′-diaminoethylpiperazine. Hydroxy heterocyclic polyamines are alsouseful. Examples include N-(2-hydroxyethyl)cyclohexylamine,3-hydroxycyclopentylamine, parahydroxyaniline, N-hydroxyethylpiperazine,and the like.

The metal salts of the phosphorus acid esters may be prepared by thereaction of a metal base with the acidic phosphorus ester. The metalbase may be any metal compound capable of forming a metal salt. Examplesof metal bases include metal oxides, hydroxides, carbonates, sulfates,borates, or the like. The metals of the metal base include Group IA,IIA, IB through VIIB, and VIII metals (CAS version of the Periodic Tableof the Elements). These metals include the alkali metals, alkaline earthmetals and transition metals. In an embodiment, the metal is a Group IIAmetal, such as calcium or magnesium, Group IIB metal, such as zinc, or aGroup VIIB metal, such as manganese. In particular embodiments, themetal is magnesium, calcium, manganese or zinc. Examples of metalcompounds which may be reacted with the phosphorus acid include zinchydroxide, zinc oxide, copper hydroxide, copper oxide, etc.

The composition of the present disclosure also may include a fattyimidazoline or a reaction product of a fatty carboxylic acid and atleast one polyamine. The fatty imidazoline has fatty substituentscontaining from 8 to about 30, or from about 12 to about 24 carbonatoms. The substituent may be saturated or unsaturated, for example,heptadeceneyl derived olyel groups. In a particular embodiment, thesubstituents are saturated. In one aspect, the fatty imidazoline may beprepared by reacting a fatty carboxylic acid with apolyalkylenepolyamine. The fatty carboxylic acids are can be mixtures ofstraight and branched chain fatty carboxylic acids containing about 8 toabout 30 carbon atoms, or from about 12 to about 24, or from about 16 toabout 18. Carboxylic acids include the polycarboxylic acids orcarboxylic acids or anhydrides having from 2 to about 4 carbonyl groups,(e.g. 2 carbonyl groups). The polycarboxylic acids include succinicacids and anhydrides and Diels-Alder reaction products of unsaturatedmonocarboxylic acids with unsaturated carboxylic acids (such as acrylic,methacrylic, maleic, fumaric, crotonic and itaconic acids). Inparticular embodiments, the fatty carboxylic acids are fattymonocarboxylic acids, having from about 8 to about 30, (e.g. about 12 toabout 24 carbon atoms), such as octanoic, oleic, stearic, linoleic,dodecanoic, and tall oil acids. In an embodiment, the fatty carboxylicacid is stearic acid. The fatty carboxylic acid or acids are reactedwith at least one polyamine. The polyamines may be aliphatic,cycloaliphatic, heterocyclic or aromatic. Examples of the polyaminesinclude alkylene polyamines and heterocyclic polyamines.

The antiwear additive according to the present disclosure has very higheffectiveness when used in low concentrations and is free of chlorine.For the neutralization of the phosphoric esters, the latter are takenand the corresponding amine slowly added with stirring. The resultingheat of neutralization is removed by cooling. The antiwear additiveaccording to the present disclosure can be incorporated into therespective base liquid with the aid of fatty substances (e.g., tall oilfatty acid, oleic acid, etc.) as solubilizers. The base liquids used arenapthenic or paraffinic base oils, synthetic oils (e.g., polyglycols,mixed polyglycols), polyolefins, carboxylic esters, etc.

In further embodiments, the compositions of the present disclosure cancontain at least one phosphorus containing antiwear additive. Examplesof such additives are amine phosphate antiwear additives such as thatknown under the trade name IRGALUBE 349 and/or triphenylphosphorothionate antiwear additives, such as that known under the tradename IRGALUBE TPPT. Such amine phosphates may be present in an amount offrom about 0.01 to about 2% (e.g. about 0.2 to about 1.5%) by weight ofthe lubricant composition, while such phosphorothionates are suitablypresent in an amount of from about 0.01 to about 3% (e.g., about 0.5 toabout 1.5%) by weight of the composition of the present disclosure. Amixture of an amine phosphate and phosphorothionate may be employed.

Neutral organic phosphates may be present in an amount from zero toabout 4% (e.g., about 0.1 to about 2.5%) by weight of the composition ofthe present disclosure. The above amine phosphates can be mixed togetherto form a single component capable of delivering antiwear performance.The neutral organic phosphate is also a conventional ingredient oflubricating oils.

Phosphates for use in the present disclosure include phosphates, acidphosphates, phosphites, and acid phosphites. The phosphates includetriaryl phosphates, trialkyl phosphates, trialkylaryl phosphates,triarylalkyl phosphates, trialkenyl phosphates, or combinations thereof.As specific examples of these, referred to are triphenyl phosphate,tricresyl phosphate, benzyldiphenyl phosphate, ethyldiphenyl phosphate,tributyl phosphate, ethyldibutyl phosphate, cresyldiphenyl phosphate,dicresylphenyl phosphate, ethylphenyldiphenyl phosphate,diethylphenylphenyl phosphate, propylphenyldiphenyl phosphate,dipropylphenylphenyl phosphate, triethylphenyl phosphate,tripropylphenyl phosphate, butylphenyldiphenyl phosphate,dibutylphenylphenyl phosphate, tributylphenyl phosphate, trihexylphosphate, tri(2-ethylhexyl) phosphate, tridecyl phosphate, trilaurylphosphate, trimyristyl phosphate, tripalmityl phosphate, tristearylphosphate, trioleyl phosphate, or combinations thereof.

The acid phosphates include, for example, 2-ethylhexyl acid phosphate,ethyl acid phosphate, butyl acid phosphate, oleyl acid phosphate,tetracosyl acid phosphate, isodecyl acid phosphate, lauryl acidphosphate, tridecyl acid phosphate, stearyl acid phosphate, isostearylacid phosphate, or combinations thereof.

The phosphites include, for example, triethyl phosphite, tributylphosphite, triphenyl phosphite, tricresyl phosphite, tri(nonylphenyl)phosphite, tri(2-ethylhexyl) phosphite, tridecyl phosphite, trilaurylphosphite, triisooctyl phosphite, diphenylisodecyl phosphite, tristearylphosphite, trioleyl phosphite, or combinations thereof.

The acid phosphites include, for example, dibutyl hydrogenphosphite,dilauryl hydrogenphosphite, dioleyl hydrogenphosphite, distearylhydrogenphosphite, diphenyl hydrogenphosphite, or combinations thereof.

Amines that form amine salts with such phosphates include, for example,mono-substituted amines, di-substituted amines and tri-substitutedamines. Examples of the mono-substituted amines include butylamine,pentylamine, hexylamine, cyclohexylamine, octylamine, laurylamine,stearylamine, oleylamine and benzylamine; and those of thedi-substituted amines include dibutylamine, dipentylamine, dihexylamine,dicyclohexylamine, dioctylamine, dilaurylamine, distearylamine,dioleylamine, dibenzylamine, stearyl monoethanolamine, decylmonoethanolamine, hexyl monopropanolamine, benzyl monoethanolamine,phenyl monoethanolamine, and tolyl monopropanolamine. Examples oftri-substituted amines include tributylamine, tripentylamine,trihexylamine, tricyclohexylamine, trioctylamine, trilaurylamine,tristearylamine, trioleylamine, tribenzylamine, dioleylmonoethanolamine, dilauryl monopropanolamine, dioctyl monoethanolamine,dihexyl monopropanolamine, dibutyl monopropanolamine, oleyldiethanolamine, stearyl dipropanolamine, lauryl diethanolamine, octyldipropanolamine, butyl diethanolamine, benzyl diethanolamine, phenyldiethanolamine, tolyl dipropanolamine, xylyl diethanolamine,triethanolamine, and tripropanolamine. Phosphates or their amine saltsare added to the base oil in an amount from zero to about 5% by weight,(e.g. from about 0.1 to about 2% by weight) relative to the total weightof the composition of the present disclosure.

Illustrative carboxylic acids to be reacted with amines include, forexample, aliphatic carboxylic acids, dicarboxylic acids (dibasic acids),aromatic carboxylic acids, or combinations thereof. The aliphaticcarboxylic acids have from 8 to 30 carbon atoms, and may be saturated orunsaturated, and linear or branched. Specific examples of the aliphaticcarboxylic acids include pelargonic acid, lauric acid, tridecanoic acid,myristic acid, palmitic acid, stearic acid, isostearic acid, eicosanoicacid, behenic acid, triacontanoic acid, caproleic acid, undecylenicacid, oleic acid, linolenic acid, erucic acid, linoleic acid, orcombinations thereof. Specific examples of the dicarboxylic acidsinclude octadecylsuccinic acid, octadecenylsuccinic acid, adipic acid,azelaic acid, sebacic acid, or combinations thereof. One example of thearomatic carboxylic acids is salicylic acid. Illustrative amines to bereacted with carboxylic acids include, for example,polyalkylene-polyamines, such as diethylenetriamine,triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine,hexaethyleneheptamine, heptaethyleneoctamine, dipropylenetriamine,tetrapropylenepentamine, hexabutyleneheptamine, or combinations thereof;and alkanolamines, such as monoethanolamine and diethanolamine. Ofthese, preferred are a combination of isostearic acid,tetraethylenepentamine, or combinations thereof; and a combination ofoleic acid and diethanolamine. Reaction products of carboxylic acids andamines may be added to the base oil in an amount of from zero to about5% by weight (e.g. from about 0.03 to about 3% by weight) relative tothe total weight of the composition of the present disclosure.

Other illustrative antiwear additives include phosphites,thiophosphites, phosphates, and thiophosphates, including mixedmaterials having, for instance, one or two sulfur atoms, i.e., monothio-or dithio compounds. As used herein, the term “hydrocarbyl substituent”or “hydrocarbyl group” is used in its ordinary sense, which iswell-known to those skilled in the art. Specifically, it refers to agroup primarily composed of carbon and hydrogen atoms and is attached tothe remainder of the molecule through a carbon atom and does not excludethe presence of other atoms or groups in a proportion insufficient todetract from the molecule having a predominantly hydrocarbon character.In general, no more than two, preferably no more than one,non-hydrocarbon substituent will be present for every ten carbon atomsin the hydrocarbyl group; typically, there will be no non-hydrocarbonsubstituents in the hydrocarbyl group. A more detailed definition of theterms “hydrocarbyl substituent” or “hydrocarbyl group,” is described inU.S. Pat. No. 6,583,092.

Specific examples of some phosphites and thiophosphites within the scopeof the disclosure include phosphorous acid, mono-, di- ortri-thiophosphorous acid, mono-, di- or tri-propyl phosphite or mono-,di- or tri-thiophosphite; mono-, di- or tri-butyl phosphite or mono-,di- or tri-thiophosphite; mono-, di- or tri-amyl phosphite or mono-, di-or tri-thiophosphite; mono-, di- or tri-hexyl phosphite; or mono-, di-or tri-thiophosphite; mono-, di- or tri-phenyl phosphite; or mono-, di-or tri-thiophosphite; mono-, di- or tri-tolyl phosphite; or mono-, di-or tri-thiophosphite; mono-, di- or tri-cresyl phosphite; or mono-, di-or tri-thiophosphite; dibutyl phenyl phosphite; or mono-, di- ortri-phosphite; amyl dicresyl phosphite; or mono-, di- ortri-thiophosphite, and any of the above with substituted groups, such aschlorophenyl or chlorobutyl.

Specific examples of the phosphates and thiophosphates within the scopeof the disclosure include phosphoric acid, mono-, di-, ortri-thiophosphoric acid, mono-, di-, or tri-propyl phosphate or mono-,di-, or tri-thiophosphate; mono-, di-, or tri-butyl phosphate or mono-,di-, or tri-thiophosphate; mono-, di-, or tri-amyl phosphate or mono-,di-, or tri-thiophosphate; mono-, di-, or tri-hexyl phosphate or mono-,di-, or tri-thiophosphate; mono-, di-, or tri-phenyl phosphate or mono-,di-, or tri-thiophosphate; mono-, di-, or tritolyl phosphate or mono-,di-, or trithiophosphate; mono-, di-, or tri-cresyl phosphate or mono-,di-, or tri-thiophosphate; dibutyl phenyl phosphate or mono-, di-, ortri-phosphate, amyl dicresyl phosphate or mono-, di-, ortri-thiophosphate, and any of the above with substituted groups, such aschlorophenyl or chlorobutyl.

These phosphorus compounds may be prepared by well-known reactions. Forexample, the reaction of an alcohol or a phenol with phosphorustrichloride or by a transesterification reaction. Alcohols and phenolscan be reacted with phosphorus pentoxide to provide a mixture of analkyl or aryl phosphoric acid and a dialkyl or diaryl phosphoric acid.Alkyl phosphates can also be prepared by the oxidation of thecorresponding phosphites. Thiophosphates can be prepared by the reactionof phosphites with elemental sulfur. In any case, the reaction can beconducted with moderate heating. Moreover, various phosphorus esters canbe prepared by reaction using other phosphorus esters as startingmaterials. Thus, medium chain (C9 to C22) phosphorus esters have beenprepared by reaction of dimethylphosphite with a mixture of medium-chainalcohols by means of a thermal transesterification or an acid- orbase-catalyzed transesterification. See, for example, U.S. Pat. No.4,752,416. Most such materials are also commercially available; forinstance, triphenyl phosphite is available from Albright and Wilson asDuraphos TPP™; di-n-butyl hydrogen phosphite from Albright and Wilson asDuraphos DBHP™; and triphenylthiophosphate from Ciba Specialty Chemicalsas Irgalube TPPT™.

Examples of esters of the dialkylphosphorodithioic acids include estersobtained by reaction of the dialkyl phosphorodithioic acid with analpha, beta-unsaturated carboxylic acid (e.g., methyl acrylate) and,optionally an alkylene oxide such as propylene oxide.

One or more of the above-identified metal dithiophosphates may be usedfrom about zero to about 2% by weight (e.g., from about 0.1 to about 1%by weight) based on the weight of the total composition.

The hydrocarbyl in the dithiophosphate may be alkyl, cycloalkyl, aralkylor alkaryl groups, or a substantially hydrocarbon group of similarstructure. Illustrative alkyl groups include isopropyl, isobutyl,n-butyl, sec-butyl, the various amyl groups, n-hexyl, methylisobutyl,heptyl, 2-ethylhexyl, diisobutyl, isooctyl, nonyl, behenyl, decyl,dodecyl, tridecyl, etc. Illustrative lower alkylphenyl groups includebutylphenyl, amylphenyl, heptylphenyl, etc. Cycloalkyl groups likewiseare useful and these include chiefly cyclohexyl and the loweralkyl-cyclohexyl radicals. Many substituted hydrocarbon groups may alsobe used, e.g., chloropentyl, dichlorophenyl, and dichlorodecyl.

The phosphorodithioic acids from which the metal salts useful in thisdisclosure are prepared are well known. Examples ofdihydrocarbylphosphorodithioic acids and metal salts, and processes forpreparing such acids and salts are found in, for example U.S. Pat. Nos.4,263,150; 4,289,635; 4,308,154; and 4,417,990. These patents are herebyincorporated by reference.

The phosphorodithioic acids may be prepared by the reaction of aphosphorus sulfide with an alcohol or phenol or mixtures of alcohols. Anexemplary reaction involves four moles of the alcohol or phenol and onemole of phosphorus pentasulfide, and may be carried out within thetemperature range from about 50° C. to about 200° C. Thus, thepreparation of O,O-di-n-hexyl phosphorodithioic acid involves thereaction of a mole of phosphorus pentasulfide with four moles of n-hexylalcohol at about 100° C. for about two hours. Hydrogen sulfide isliberated and the residue is the desired acid. The preparation of themetal salts of these acids may be effected by reaction with metalcompounds as well known in the art.

The metal salts of dihydrocarbyldithiophosphates, which are useful inthe present disclosure, include those salts containing Group I metals,Group II metals, aluminum, lead, tin, molybdenum, manganese, cobalt, andnickel. The Group II metals, aluminum, tin, iron, cobalt, lead,molybdenum, manganese, nickel and copper are among the preferred metals.Zinc and copper are especially useful metals. Examples of metalcompounds which may be reacted with the acid include lithium oxide,lithium hydroxide, sodium hydroxide, sodium carbonate, potassiumhydroxide, potassium carbonate, silver oxide, magnesium oxide, magnesiumhydroxide, calcium oxide, zinc hydroxide, strontium hydroxide, cadmiumoxide, cadmium hydroxide, barium oxide, aluminum oxide, iron carbonate,copper hydroxide, lead hydroxide, tin butylate, cobalt hydroxide, nickelhydroxide, nickel carbonate, and the like.

In some instances, the incorporation of certain ingredients such assmall amounts of the metal acetate or acetic acid in conjunction withthe metal reactant will facilitate the reaction and result in animproved product. For example, the use of up to about 5% of zinc acetatein combination with the required amount of zinc oxide facilitates theformation of a zinc phosphorodithioate with potentially improvedperformance properties.

Especially useful metal phosphorodithloates can be prepared fromphosphorodithloic acids, which in turn are prepared by the reaction ofphosphorus pentasulfide with mixtures of alcohols. In addition, the useof such mixtures enables the utilization of less expensive alcohols,which individually may not yield oil-soluble phosphorodithioic acids.Thus, a mixture of isopropyl and hexylalcohols can be used to produce avery effective, oil-soluble metal phosphorodithioate. For the samereason mixtures of phosphorodithioic acids can be reacted with the metalcompounds to form less expensive, oil-soluble salts.

The mixtures of alcohols may be mixtures of different primary alcohols,mixtures of different secondary alcohols, or mixtures of primary andsecondary alcohols. Examples of useful mixtures include: n-butanol andn-octanol; n-pentanol and 2-ethyl-1-hexanol; isobutanol and n-hexanol;isobutanol and isoamyl alcohol; isopropanol and 2-methyl-4-pentanol;isopropanol and sec-butyl alcohol; isopropanol and isooctyl alcohol; andthe like.

Organic triesters of phosphorus acids are also employed in lubricants.Exemplary esters include triarylphosphates, trialkyl phosphates, neutralalkylaryl phosphates, alkoxyalkyl phosphates, triaryl phosphite,trialkylphosphite, neutral alkyl aryl phosphites, neutral phosphonateesters and neutral phosphine oxide esters. In one embodiment, the longchain dialkyl phosphonate esters are used. For example, the dimethyl-,diethyl-, and/or dipropyl-oleyl phohphonates can be used. Neutral acidsof phosphorus acids are the triesters rather than an acid (HO-P) or asalt of an acid.

Any C4 to C8 alkyl or higher phosphate ester may be employed in thedisclosure. For example, tributyl phosphate (TBP) and tri isooctalphosphate (TOF) can be used. The specific triphosphate ester orcombination of esters can easily be selected by one skilled in the artto adjust the density, viscosity, etc., of the formulated fluid. Mixedesters, such as dibutyl octyl phosphate or the like may be employedrather than a mixture of two or more trialkyl phosphates.

A trialkyl phosphate is often useful to adjust the specific gravity ofthe formulation, but it is desirable that the specific trialkylphosphate be a liquid at low temperatures. Consequently, a mixed estercontaining at least one partially alkylated with a C3 to C4 alkyl groupis very desirable, for example, 4-isopropylphenyl diphenyl phosphate or3-butylphenyl diphenyl phosphate. Even more desirable is a triarylphosphate produced by partially alkylating phenol with butylene orpropylene to form a mixed phenol which is then reacted with phosphorusoxychloride as taught in U.S. Pat. No. 3,576,923.

Any mixed triaryl phosphate (TAP) esters may be used as cresyl diphenylphosphate, tricresyl phosphate, mixed xylyl cresyl phosphates, loweralkylphenyl/phenyl phosphates, such as mixed isopropylphenyl/phenylphosphates, t-butylphenyl phenyl phosphates. These esters are usedextensively as plasticizers, functional fluids, gasoline additives,flame-retardant additives and the like.

A metal alkylthiophosphate and more particularly a metal dialkyl dithiophosphate in which the metal constituent is zinc, or zinc dialkyl dithiophosphate (ZDDP) can be a useful component of the lubricating oils ofthis disclosure. ZDDP can be derived from primary alcohols, secondaryalcohols or mixtures thereof. ZDDP compounds are of the formula:

Zn[SP(S)(OR1)(OR2)]₂,

wherein R1 and R2 are C1-C18 alkyl groups (e.g. C2-C12 alkyl groups).

These alkyl groups may be straight chain or branched. Alcohols used inthe ZDDP can be propanol, 2-propanol, butanol, secondary butanol,pentanols, hexanols such as 4-methyl-2-pentanol, n-hexanol, n-octanol,2-ethyl hexanol, alkylated phenols, and the like. Mixtures of secondaryalcohols or of primary and secondary alcohol can be utilized. Alkyl arylgroups may also be used.

Exemplary zinc dithiophosphates that are commercially available includesecondary zinc dithiophosphates, such as those available from forexample, The Lubrizol Corporation under the trade designations “LZ677A”, “LZ 1095” and “LZ 1371”, from for example Chevron Oronite underthe trade designation “OLOA 262”, and from for example Afton Chemicalunder the trade designation “HITEC 7169”.

ZDDP may be used in amounts of from about zero to about 3 weight percent(e.g. from about 0.05 weight percent to about 2 weight percent, fromabout 0.1 weight percent to about 1.5 weight percent, or from about 0.1weight percent to about 1 weight percent) based on the total weight ofthe composition fo the present disclosure, although more or less canoften be used advantageously. A secondary ZDDP may be present in anamount of from zero to about 1 weight percent of the total weight of thecomposition of the present disclosure.

Extreme Pressure Agent(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one (e.g., 1, 2, 3, or 4, or more)extreme pressure agent. Any extreme pressure agent that is known or thatbecomes know may be utilized in the composition of the presentdisclosure.

The extreme pressure agents can be at least one sulfur-based extremepressure agents, such as sulfides, sulfoxides, sulfones,thiophosphinates, thiocarbonates, sulfurized fats and oils, sulfurizedolefins, the like, or combinations thereof at least one phosphorus-basedextreme pressure agents, such as phosphoric acid esters (e.g., tricresylphosphate (TCP) and the like), phosphorous acid esters, phosphoric acidester amine salts, phosphorous acid ester amine salts, the like, orcombinations thereof; halogen-based extreme pressure agents, such aschlorinated hydrocarbons, the like, or combinations thereof;organometallic extreme pressure agents, such as thiophosphoric acidsalts (e.g., zinc dithiophosphate (ZnDTP) and the like), thiocarbamicacid salts, or combinations thereof; and the like.

The phosphoric acid ester, thiophosphoric acid ester, and amine saltsthereof functions to enhance the lubricating performances, and can beselected from known compounds conventionally employed as extremepressure agents. For example, phosphoric acid esters, a thiophosphoricacid ester, or an amine salt thereof which has an alkyl group, analkenyl group, an alkylaryl group, or an aralkyl group, any of whichcontains approximately 3 to 30 carbon atoms, may be employed.

Examples of the phosphoric acid esters include aliphatic phosphoric acidesters such as triisopropyl phosphate, tributyl phosphate, ethyl dibutylphosphate, trihexyl phosphate, tri-2-ethylhexyl phosphate, trilaurylphosphate, tristearyl phosphate, and trioleyl phosphate; and aromaticphosphoric acid esters such as benzyl phenyl phosphate, allyl diphenylphosphate, triphenyl phosphate, tricresyl phosphate, ethyl diphenylphosphate, cresyl diphenyl phosphate, dicresyl phenyl phosphate,ethylphenyl diphenyl phosphate, diethylphenyl phenyl phosphate,propylphenyl diphenyl phosphate, dipropylphenyl phenyl phosphate,triethylphenyl phosphate, tripropylphenyl phosphate, butylphenyldiphenyl phosphate, dibutylphenyl phenyl phosphate, and tributylphenylphosphate. In an embodiment, the phosphoric acid ester is atrialkylphenyl phosphate.

Examples of the thiophosphoric acid esters include aliphaticthiophosphoric acid esters such as triisopropyl thiophosphate, tributylthiophosphate, ethyl dibutyl thiophosphate, trihexyl thiophosphate,tri-2-ethylhexyl thiophosphate, trilauryl thiophosphate, tristearylthiophosphate, and trioleyl thiophosphate; and aromatic thiophosphoricacid esters such as benzyl phenyl thiophosphate, allyl diphenylthiophosphate, triphenyl thiophosphate, tricresyl thiophosphate, ethyldiphenyl thiophosphate, cresyl diphenyl thiophosphate, dicresyl phenylthiophosphate, ethylphenyl diphenyl thiophosphate, diethylphenyl phenylthiophosphate, propylphenyl diphenyl thiophosphate, dipropylphenylphenyl thiophosphate, triethylphenyl thiophosphate, tripropylphenylthiophosphate, butylphenyl diphenyl thiophosphate, dibutylphenyl phenylthiophosphate, and tributylphenyl thiophosphate. In an embodiment, thethiophosphoric acid ester is a trialkylphenyl thiophosphate.

Also employable are amine salts of the above-mentioned phosphates andthiophosphates. Amine salts of acidic alkyl or aryl esters of thephosphoric acid and thiophosphoric acid are also employable. In anembodiment, the amine salt is an amine salt of trialkylphenyl phosphateor an amine salt of alkyl phosphate.

One or any combination of the compounds selected from the groupconsisting of a phosphoric acid ester, a thiophosphoric acid ester, andan amine salt thereof may be used.

The phosphorus acid ester and/or its amine salt function to enhance thelubricating performance of the composition, and can be selected fromknown compounds conventionally employed as extreme pressure agents. Forexample, the extreme pressure agent can be a phosphorus acid ester or anamine salt thereof, which has an alkyl group, an alkenyl group, analkylaryl group, or an aralkyl group, any of which containsapproximately 3 to 30 carbon atoms.

Examples of phosphorus acid esters that may be used includes aliphaticphosphorus acid esters, such as triisopropyl phosphite, tributylphosphite, ethyl dibutyl phosphite, trihexyl phosphite,tri-2-ethylhexylphosphite, trilauryl phosphite, tristearyl phosphite,and trioleyl phosphite; and aromatic phosphorus acid esters such asbenzyl phenyl phosphite, allyl diphenylphosphite, triphenyl phosphite,tricresyl phosphite, ethyl diphenyl phosphite, tributyl phosphite, ethyldibutyl phosphite, cresyl diphenyl phosphite, dicresyl phenyl phosphite,ethylphenyl diphenyl phosphite, diethylphenyl phenyl phosphite,propylphenyl diphenyl phosphite, dipropylphenyl phenyl phosphite,triethylphenyl phosphite, tripropylphenyl phosphite, butylphenyldiphenyl phosphite, dibutylphenyl phenyl phosphite, and tributylphenylphosphite. Also favorably employed are dilauryl phosphite, dioleylphosphite, dialkyl phosphites, and diphenyl phosphite. In certainembodiments, the phosphorus acid ester is a dialkyl phosphite or atrialkyl phosphite.

The phosphate salt may be derived from a polyamine, such as alkoxylateddiamines, fatty polyamine diamines, alkylenepolyamines, hydroxycontaining polyamines, condensed polyamines arylpolyamines, andheterocyclic polyamines. Examples of these amines include EthoduomeenT/13 and T/20, which are ethylene oxide condensation products ofN-tallowtrimethylenediamine containing 3 and 10 moles of ethylene oxideper mole of diamine, respectively.

In another embodiment, the polyamine is a fatty diamine. The fattydiamine may include mono- or dialkyl, symmetrical or asymmetricalethylene diamines, propane diamines (1,2 or 1,3), and polyamine analogsof the above. Suitable commercial fatty polyamines are Duomeen C(N-coco-1,3-diaminopropane), Duomeen S (N-soya-1,3-diaminopropane),Duomeen T (N-tallow-1,3-diaminopropane), and Duomeen 0(N-oleyl-1,3-diaminopropane). “Duomeens” are commercially available fromArmak Chemical Co., Chicago, Ill.

Such alkylenepolyamines include methylenepolyamines, ethylenepolyamines,butylenepolyamines, propylenepolyamines, pentylenepolyamines, etc. Thehigher homologs and related heterocyclic amines, such as piperazines andN-amino alkyl-substituted piperazines, are also included. Specificexamples of such polyamines are ethylenediamine, triethylenetetramine,tris-(2-aminoethyl)amine, propylenediamine, trimethylenediamine,tripropylenetetramine, tetraethylenepentamine, hexaethyleneheptamine,pentaethylenehexamine, etc. Higher homologs obtained by condensing twoor more of the above-noted alkyleneamines are similarly useful as aremixtures of two or more of the aforedescribed polyamines.

In one embodiment the polyamine is an ethylenepolyamine. Such polyaminesare described in detail under the heading Ethylene Amines in KirkOthmer's “Encyclopedia of Chemical Technology”, 2nd Edition, Vol. 7,pages 22-37, Interscience Publishers, New York (1965).Ethylenepolyamines can be a complex mixture of polyalkylenepolyamines,including cyclic condensation products.

Other useful types of polyamine mixtures are those resulting fromstripping of the above-described polyamine mixtures to leave, asresidue, what is often termed “polyamine bottoms”. The alkylenepolyaminebottoms can be characterized as having less than 2%, usually less than1% (by weight) material boiling below about 200° C. An exemplary sampleof such ethylene polyamine bottoms obtained from the Dow ChemicalCompany of Freeport, Tex. designated “E-100”. These alkylenepolyaminebottoms include cyclic condensation products, such as piperazine, andhigher analogs of diethylenetriamine, triethylenetetramine and the like.These alkylenepolyamine bottoms can be reacted solely with the acylatingagent or they can be used with other amines, polyamines, or mixturesthereof. Another useful polyamine is a condensation reaction between atleast one hydroxy compound with at least one polyamine reactantcontaining at least one primary or secondary amino group. In anembodiment, the hydroxy compounds are alcohols and amines. Thepolyhydric alcohols are described below. In one embodiment, the hydroxycompounds are polyhydric amines. Polyhydric amines include any of theabove-described monoamines reacted with an alkylene oxide (e.g.,ethylene oxide, propylene oxide, butylene oxide, etc.) having from twoto about 20 carbon atoms, or from two to about four. Examples ofpolyhydric amines include tri-(hydroxypropyl)amine,tris-(hydroxymethyl)amino methane, 2-amino-2-methyl-1,3-propanediol,N,N,N′,N′-tetrakis(2-hydroxypropyl)ethylenediamine, andN,N,N′,N′-tetrakis(2-hydroxyethyl)ethylenediamine. IN an embodiment, thepolyhydric amin is tris(hydroxymethyl)aminomethane (THAM).

Polyamines which react with the polyhydric alcohol or amine to form thecondensation products or condensed amines, are described above. In anembodiment, the polyamine includes at least one of triethylenetetramine(TETA), tetraethylenepentamine (TEPA), pentaethylenehexamine (PEHA), andmixtures of polyamines, such as the above-described “amine bottoms”.

In some embodiments, the extreme pressure additive or additives includessulphur-based extreme pressure additives, such as dialkyl sulphides,dibenzyl sulphide, dialkyl polysulphides, dibenzyl disulphide, alkylmercaptans, dibenzothiophene, 2,2′-dithiobis(benzothiazole), orcombinations thereof phosphorus-based extreme pressure additives, suchas trialkyl phosphates, triaryl phosphates, trialkyl phosphonates,trialkyl phosphites, triaryl phosphites, dialkylhydrozine phosphites, orcombinations thereof and/or phosphorus- and sulphur-based extremepressure additives, such as zinc dialkyldithiophosphates,dialkylthiophosphoric acid, trialkyl thiophosphate esters, acidicthiophosphate esters, trialkyl trithiophosphates, or combinationsthereof. Extreme pressure additives can be used individually or in theform of mixtures, conveniently in an amount within the range from zeroto about 2% by weight of the composition of the present disclosure.

Dispersant(s)

In other embodiments, the composition of the present disclosurecomprises at least one (e.g., 1, 2, 3, or 4, or more) dispersant. Duringmachine operation, oil-insoluble oxidation byproducts are produced. Thedispersant may be added to help keep these byproducts in solution, thusdiminishing their deposition on metal surfaces. Any dispersant that isknown or that becomes know may be utilized in the composition of thepresent disclosure. The dispersant may be present in an amount of about1.5 wt. %, about 1.25 wt. %, or about 1 wt. %. For example, thedispersant may be present in an amount of about 0.1 to about 1.5 wt. %,about 0.1 to about 1.25 wt. %, about 0.1 to about 1 wt. %, about 0.1 toabout 0.5 wt. %, about 0.25 to about 1.5 wt. %, about 0.25 to about 1.25wt. %, about 0.5 to about 1 wt. %, about 0.5 to about 1.5 wt. %, about0.5 to about 1.25 wt. %, about 0.5 to about 1 wt. %, about 0.75 to about1.5 wt. %, about 0.75 to about 1.25 wt. %, or about 1 to about 1.5 wt.%.

In some embodiments, the dispersants are ashless or ash-forming innature. In an embodiment, the dispersant is an ashless. The so calledashless are organic materials that form substantially no ash uponcombustion. For example, non-metal-containing or borated metal-freedispersants are considered ashless. In contrast, metal-containingdetergents form ash upon combustion.

Suitable dispersants may contain a polar group attached to a relativelyhigh molecular weight hydrocarbon chain (e.g., about 50 to about 400carbon atoms). In certain embodiments, the polar group contains at leastone element of nitrogen, oxygen, or phosphorus.

A particularly useful class of dispersants are the (poly)alkenylsuccinicderivatives, which may be produced by the reaction of a long chainhydrocarbyl substituted succinic compound, e.g. a hydrocarbylsubstituted succinic anhydride, with a polyhydroxy or polyaminocompound. The long chain hydrocarbyl group constituting the oleophilicportion of the molecule, which confers solubility in the oil, isnormally a polyisobutylene group. Many examples of this type ofdispersant are well known commercially and in the literature. ExemplaryU.S. patents describing such dispersants are U.S. Pat. Nos. 3,172,892;3,215,707; 3,219,666; 3,316,177; 3,341,542; 3,444,170; 3,454,607;3,541,012; 3,630,904; 3,632,511; 3,787,374 and 4,234,435. Other types ofdispersant are described in U.S. Pat. Nos. 3,036,003; 3,200,107;3,254,025; 3,275,554; 3,438,757; 3,454,555; 3,565,804; 3,413,347;3,697,574; 3,725,277; 3,725,480; 3,726,882; 4,454,059; 3,329,658;3,449,250; 3,519,565; 3,666,730; 3,687,849; 3,702,300; 4,100,082;5,705,458. A further description of dispersants may be found, forexample, in European Patent Application No. 471 071, to which referenceis made for this purpose.

Hydrocarbyl-substituted succinic acid and hydrocarbyl-substitutedsuccinic anhydride derivatives are useful dispersants. In particular,succinimide, succinate esters, or succinate ester amides prepared by thereaction of a hydrocarbon-substituted succinic acid compound (e.g., ahydrocarbon-substituted succinic acid compound having at least 50 carbonatoms in the hydrocarbon substituent) with at least one equivalent of analkylene amine are particularly useful.

Succinimides are formed by the condensation reaction between hydrocarbylsubstituted succinic anhydrides and amines. Molar ratios can varydepending on the polyamine. For example, the molar ratio of hydrocarbylsubstituted succinic anhydride to TEPA can vary from about 1:1 to about5:1. Representative examples are shown in U.S. Pat. Nos. 3,087,936;3,172,892; 3,219,666; 3,272,746; 3,322,670; and 3,652,616, 3,948,800;and Canada Patent No. 1,094,044.

Succinate esters may be formed by the condensation reaction betweenhydrocarbyl substituted succinic anhydrides and alcohols or polyols.Molar ratios can vary depending on the alcohol or polyol used. Forexample, the condensation product of a hydrocarbyl substituted succinicanhydride and pentaerythritol is a useful dispersant.

Succinate ester amides may be formed by condensation reaction betweenhydrocarbyl substituted succinic anhydrides and alkanol amines. Forexample, suitable alkanol amines include ethoxylatedpolyalkylpolyamines, propoxylated polyalkylpolyamines andpolyalkenylpolyamines, such as polyethylene polyamines. One example ispropoxylated hexamethylenediamine. Representative examples are shown inU.S. Pat. No. 4,426,305.

The molecular weight of the hydrocarbyl substituted succinic anhydridesused in the preceding paragraphs can range between about 800 and about2,500 or more. The above products can be post-reacted with variousreagents such as sulfur, oxygen, formaldehyde, carboxylic acids, such asoleic acid. The above products can also be post reacted with boroncompounds, such as boric acid, borate esters or highly borateddispersants, to form borated dispersants, which may have from about 0.1to about 5 moles of boron per mole of dispersant reaction product.

Mannich base dispersants are made from the reaction of alkylphenols,formaldehyde, and amines. See U.S. Pat. No. 4,767,551, which isincorporated herein by reference. Process aids and catalysts, such asoleic acid and sulfonic acids, can also be part of the reaction mixture.Molecular weights of the alkylphenols may range from about 800 to about2,500. Representative examples are shown in U.S. Pat. Nos. 3,697,574;3,703,536; 3,704,308; 3,751,365; 3,756,953; 3,798,165; and 3,803,039.

High molecular weight aliphatic acid modified Mannich condensationproducts useful in this disclosure can be prepared from high molecularweight alkyl-substituted hydroxyaromatics or HNR2 group-containingreactants, wherein each R is independently selected from hydrogen,C1-C18 alkyl, aryl, alkenyl, alkaryl group.

Hydrocarbyl substituted amine ashless dispersant additives are wellknown to one skilled in the art; see, for example, U.S. Pat. Nos.3,275,554; 3,438,757; 3,565,804; 3,755,433, 3,822,209, and 5,084,197.

In certain embodiments, the dispersants include borated and/ornon-borated succinimides, including those derivatives frommono-succinimides, bis-succinimides, and/or mixtures of mono- andbis-succinimides, wherein the hydrocarbyl succinimide is derived from ahydrocarbylene group such as polyisobutylene having a Mn of from about500 to about 5000, or from about 1000 to about 3000, or about 1000 toabout 2000, or a mixture of such hydrocarbylene groups, often with highterminal vinylic groups. Other dispersants include succinic acid-estersand amides, alkylphenol-polyamine-coupled Mannich adducts, their cappedderivatives, and other related components.

Polymethacrylate or polyacrylate derivatives are another class ofdispersants. These dispersants may be prepared by reacting a nitrogencontaining monomer and a methacrylic or acrylic acid esters containingabout 5 to about 25 carbon atoms in the ester group. Representativeexamples are shown in U.S. Pat. Nos. 2,100,993, and 6,323,164.Polymethacrylate and polyacrylate dispersants may be used asmultifunctional viscosity modifiers. The lower molecular weight versionscan be used as lubricant dispersants or fuel detergents.

Illustrative dispersants useful in this disclosure include those derivedfrom polyalkenyl-substituted mono- or dicarboxylic acid, anhydride orester, wherein the polyalkenyl moiety has an average molecular weight ofat least about 900 and from greater than 1.3 to 1.7 (e.g. from greaterthan 1.3 to 1.6 or from greater than 1.3 to 1.5) functional groups(mono- or dicarboxylic acid producing moieties) per polyalkenyl moiety(a medium functionality dispersant). Functionality (F) can be determinedaccording to the following formula:

F=(SAP×Mn)/((112,200×A.I.)−(SAP×98)),

wherein:SAP is the saponification number (i.e., the number of milligrams of KOHconsumed in the complete neutralization of the acid groups in one gramof the succinic-containing reaction product, as determined according toASTM D94);Mn is the number average molecular weight of the starting olefinpolymer; andA.I. is the percent active ingredient of the succinic-containingreaction product (the remainder being unreacted olefin polymer, succinicanhydride and diluent).

The polyalkenyl moiety of the dispersant may have a number averagemolecular weight of at least about 900 or suitably at least about 1500,such as between about 1800 and about 3000 (e.g. between about 2000 andabout 2800, from about 2100 to about 2500, or from about 2200 to about2400). The molecular weight of a dispersant is generally expressed interms of the molecular weight of the polyalkenyl moiety. This is becausethe precise molecular weight range of the dispersant depends on numerousparameters including the type of polymer used to derive the dispersant,the number of functional groups, and the type of nucleophilic groupemployed.

Polymer molecular weight, specifically Mn, can be determined by variousknown techniques. One convenient method is gel permeation chromatography(GPC), which additionally provides molecular weight distributioninformation (see W. W. Yau, J. J. Kirkland and D. D. Bly, “Modem SizeExclusion Liquid Chromatography”, John Wiley and Sons, New York, 1979).Another useful method for determining molecular weight, particularly forlower molecular weight polymers, is vapor pressure osmometry (e.g., ASTMD3592).

In an embodiment, the polyalkenyl moiety in a dispersant has a narrowmolecular weight distribution (MWD), also referred to as polydispersity,as determined by the ratio of weight average molecular weight (Mw) tonumber average molecular weight (Mn). Polymers having a Mw/Mn of lessthan 2.2 (e.g. less than 2.0) are most desirable. Suitable polymers havea polydispersity of from about 1.5 to 2.1 (e.g. from about 1.6 to about1.8).

Suitable polyalkenes employed in the formation of the dispersantsinclude homopolymers, interpolymers or lower molecular weighthydrocarbons. One family of such polymers comprise polymers of ethyleneand/or at least one C3 to C26 alpha-olefin having the formula:

H₂C═CHR⁶,

wherein R⁶ is a straight or branched chain alkyl radical comprising 1 to26 carbon atoms and wherein the polymer contains carbon-to-carbonunsaturation, and a high degree of terminal ethenylidene unsaturation.In an embodiment, such polymers comprise interpolymers of ethylene andat least one alpha-olefin of the above formula, wherein R⁶ is alkyl offrom 1 to 18 carbon atoms (e.g. from 1 to 8 carbon atoms or from 1 to 2carbon atoms).

Another useful class of polymers is polymers prepared by cationicpolymerization of monomers such as isobutene and styrene. For example,the polymer(s) can be polyisobutenes obtained by polymerization of a C4refinery stream having a butene content of 35 to 75% by wt., and anisobutene content of 30 to 60% by wt. Petroleum feestreams, such asRaffinate II, can be a source of monomer for making poly-n-butenes.These feedstocks are disclosed in the art such as in U.S. Pat. No.4,952,739. Certain embodiments utilize polyisobutylene prepared from apure isobutylene stream or a Raffinate I stream to prepare reactiveisobutylene polymers with terminal vinylidene olefins. Polyisobutenepolymers that may be employed may be based on a polymer chain of fromabout 1500 to about 3000.

In yet further embodiments, the dispersant(s) are non-polymeric (e.g.,mono- or bis-succinimides). Such dispersants can be prepared byconventional processes, such as those disclosed in U.S. PatentApplication Publication No. 2008/0020950, the disclosure of which isincorporated herein by reference.

The dispersant(s) can be borated by conventional means, as generallydisclosed in U.S. Pat. Nos. 3,087,936, 3,254,025 and 5,430,105.

Dispersants may be used in an amount of zero to about 10 weight percentor about 0.01 to about 8 weight percent (e.g. about 0.1 to about 5weight percent or about 0.5 to about 3 weight percent). Or suchdispersants may be used in an amount of zero to about 8 weight percent(e.g. about 0.01 to about 5 weight percent or about 0.1 to about 3weight percent). On an active ingredient basis, such additives may beused in an amount of zero to about 10 weight percent (e.g. about 0.3 toabout 3 weight percent). The hydrocarbon portion of the dispersant atomscan range from about C60 to about C1000, or from about C70 to aboutC300, or from about C70 to about C200. These dispersants may containboth neutral and basic nitrogen, and mixtures thereof. Dispersants canbe end-capped by borates and/or cyclic carbonates. Nitrogen content inthe finished oil can vary from about zero to about 2000 ppm by weight(e.g. from about 100 ppm by weight to about 1200 ppm by weight). Basicnitrogen can vary from about zero to about 1000 ppm by weight (e.g. fromabout 100 ppm by weight to about 600 ppm by weight).

Dispersants as described herein are beneficially useful with thecompositions of the present disclosure. Further, in one embodiment,preparation of the compositions of the present disclosure using one ormore (e.g. 1, 2, 3, 4, or more) dispersants is achieved by combiningingredients of the present disclosure, plus optional base stocks andlubricant additives, in a mixture at a temperature above the meltingpoint of such ingredients, particularly that of the one or moreM-carboxylates (M=H, metal, two or more metals, mixtures thereof).

As used herein, the dispersant concentrations are given on an “asdelivered” basis. The active dispersant may be delivered with a processoil. The “as delivered” dispersant may contain from about 20 weightpercent to about 80 weight percent, or from about 40 weight percent toabout 60 weight percent, of active dispersant in the “as delivered”dispersant product.

Friction Modifier(s)

In any aspect or embodiment described herein, the composition of thepresent disclosure comprises at least one (e.g., 1, 2, 3, or 4, or more)friction modifier. A friction modifier is any material or materials thatcan alter the coefficient of friction of a surface lubricated by anylubricant or fluid containing such material(s). Friction modifiers, alsoknown as friction reducers, or lubricity agents or oiliness agents, andother such agents that change the ability of base oils, formulatedlubricant compositions, or functional fluids, to modify the coefficientof friction of a lubricated surface may be effectively used incombination with the base oils or lubricant compositions of the presentdisclosure if desired. Friction modifiers that lower the coefficient offriction are particularly advantageous in combination with the base oilsand lube compositions of this disclosure. Any friction modifier that isknown or that becomes know may be utilized in the composition of thepresent disclosure.

Friction modifiers may include, for example, organometallic compounds ormaterials, or mixtures thereof. Illustrative organometallic frictionmodifiers useful in the lubricating oil formulations of this disclosureinclude, for example, molybdenum amine, molybdenum diamine, anorganotungstenate, a molybdenum dithiocarbamate, molybdenumdithiophosphates, molybdenum amine complexes, molybdenum carboxylates,and the like, and mixtures thereof. In an embodiment, tungsten-basedcompounds are utilized.

Other illustrative friction modifiers useful in the lubricatingformulations of the present disclosure include, for example, alkoxylatedfatty acid esters, alkanolamides, polyol fatty acid esters, boratedglycerol fatty acid esters, fatty alcohol ethers, and mixtures thereof.

Illustrative alkoxylated fatty acid esters include, for example,polyoxyethylene stearate, fatty acid polyglycol ester, and the like.These can include polyoxypropylene stearate, poly oxybutylene stearate,polyoxyethylene isosterate, polyoxypropylene isostearate,polyoxyethylene palmitate, and the like.

Illustrative alkanolamides include, for example, lauric aciddiethylalkanolamide, palmic acid diethylalkanolamide, and the like.These can include oleic acid diethyalkanolamide, stearic aciddiethylalkanolamide, oleic acid diethylalkanolamide, polyethoxylatedhydrocarbylamides, polypropoxylated hydrocarbylamides, and the like.

Illustrative polyol fatty acid esters include, for example, glycerolmono-oleate, saturated mono-, di-, and tri-glyceride esters, glycerolmono-stearate, and the like. These can include polyol esters,hydroxyl-containing polyol esters, and the like.

Illustrative borated glycerol fatty acid esters include, for example,borated glycerol mono-oleate, borated saturated mono-, di-, andtri-glyceride esters, borated glycerol mono-sterate, and the like. Inaddition to glycerol polyols, these can include trimethylolpropane,pentaerythritol, sorbitan, and the like. These esters can be polyolmonocarboxylate esters, polyol dicarboxylate esters, and on occasionpolyoltricarboxylate esters. In certain embodiments, the frictionmodifier is glycerol mono-oleates, glycerol dioleates, glyceroltrioleates, glycerol monostearates, glycerol distearates, and glyceroltristearates and the corresponding glycerol monopalmitates, glyceroldipalmitates, glycerol tripalmitates, or the respective isostearates,linoleates, and the like, or combinations thereof. In an embodiment, thefriction modifier is a glycerol esters or mixtures containing any ofthese. Ethoxylated, propoxylated, butoxylated fatty acid esters ofpolyols, especially using glycerol as underlying polyol can be utilized.

Illustrative fatty alcohol ethers include, for example, stearyl ether,myristyl ether, and the like. Alcohols, including those that have carbonnumbers from C3 to C50, can be ethoxylated, propoxylated, or butoxylatedto form the corresponding fatty alkyl ethers. The underlying alcoholportion can be, e.g., stearyl, myristyl, C11-C13 hydrocarbon, oleyl,isosteryl, and the like.

Other friction modifiers could be optionally included in addition to thefatty phosphites and fatty imidazolines. A useful list of such otherfriction modifier additives is included in U.S. Pat. No. 4,792,410. U.S.Pat. No. 5,110,488 discloses metal salts of fatty acids and especiallyzinc salts, useful as friction modifiers. Fatty acids are also usefulfriction modifiers. A list of other suitable friction modifiers includesat least one of: (i) fatty phosphonates; (ii) fatty acid amides; (iii)fatty epoxides; (iv) borated fatty epoxides; (v) fatty amines; (vi)glycerol esters; (vii) borated glycerol esters; (viii) alkoxylated fattyamines; (ix) borated alkoxylated fatty amines; (x) metal salts of fattyacids; (xi) sulfurized olefins; (xii) condensation products ofcarboxylic acids or equivalents and polyalkylene-polyamines; (xiii)metal salts of alkyl salicylates; (xiv) amine salts of alkylphosphoricacids; (xv) fatty esters; (xvi) condensation products of carboxylicacids; or equivalents with polyols and mixtures thereof.

Representatives of each of these types of friction modifiers are knownand are commercially available. For instance, (i) includes components ofthe formulas:

(RO)2PHO,

(RO)(HO)PHO, and

P(OR)(OR)(OR),

wherein, in these structures, the each “R” is conventionally referred toas an alkyl group, but may also be hydrogen. It is, of course, possiblethat the alkyl group is actually alkenyl and thus the terms “alkyl” and“alkylated,” as used herein, will embrace other than saturated alkylgroups within the component. The component should have sufficienthydrocarbyl groups to render it substantially oleophilic. In someembodiments, the hydrocarbyl groups are substantially un-branched. Manysuitable such components are available commercially and may besynthesized as described in U.S. Pat. No. 4,752,416. In someembodiments, the component contains 8 to 24 carbon atoms in each of theR groups. In other embodiments, the component may be a fatty phosphitecontaining 12 to 22 carbon atoms in each of the fatty radicals, or 16 to20 carbon atoms. In one embodiment the fatty phosphite can be formedfrom oleyl groups, thus having 18 carbon atoms in each fatty radical.

The (iv) borated fatty epoxides are known from Canadian Patent No.1,188,704. These oil-soluble boron-containing compositions are preparedby reacting, at a temperature from 80° C. to 250° C., boric acid orboron trioxide with at least one fatty epoxide having the formula:

wherein each of R⁷, R⁸, R⁹ and R¹⁹ is independently hydrogen or analiphatic radical, or any two thereof together with the epoxy carbonatom or atoms to which they are attached, form a cyclic radical. In anembodiment, the fatty epoxide contains at least 8 carbon atoms.

The borated fatty epoxides can be characterized by the method for theirpreparation which involves the reaction of two materials. Reagent A canbe boron trioxide or any of the various forms of boric acid includingmetaboric acid (HBO₂), orthoboric acid (H₃BO₃) and tetraboric acid(H₂B₄O₇). In an embodiment, Reagent A is boric acid, such as orthoboricacid. Reagent B can be at least one fatty epoxide having the aboveformula. In the formula, each of the R groups is most often hydrogen oran aliphatic radical with at least one being a hydrocarbyl or aliphaticradical containing at least 6 carbon atoms. The molar ratio of reagent Ato reagent B may be about 1:0.25 to about 1:4 (e.g. about 1:1 to about1:3 or about 1:2). The borated fatty epoxides can be prepared by merelyblending the two reagents and heating them at temperature of about 80°C. to about 250° C., such as about 100° C. to about 200° C., for aperiod of time sufficient for reaction to take place. If desired, thereaction may be effected in the presence of a substantially inert,normally liquid organic diluent. During the reaction, water is evolvedand may be removed by distillation.

The (iii) non-borated fatty epoxides, corresponding to Reagent B above,are also useful as friction modifiers.

Borated amines are generally known from U.S. Pat. No. 4,622,158. Boratedamine friction modifiers (including (ix) borated alkoxylated fattyamines) can be prepared by the reaction of a boron compounds, asdescribed above, with the corresponding amines. The amine can be asimple fatty amine or hydroxy containing tertiary amines. The boratedamines can be prepared by adding the boron reactant, as described above,to an amine reactant and heating the resulting mixture at about 50° C.to about 300° C. (e.g. about 100° C. to about 250° C. or about 130° C.to about 180° C.) with stirring. The reaction is continued untilby-product water ceases to evolve from the reaction mixture indicatingcompletion of the reaction.

Among the amines useful in preparing the borated amines are commercialalkoxylated fatty amines known by the trademark “ETHOMEEN” and availablefrom Akzo Nobel. Representative examples of these ETHOMEEN™ materials isETHOMEEN™ C/12 (bis[2-hydroxyethyl]-coco-amine); ETHOMEEN™ C/20(polyoxyethylene¬[10]cocoamine); ETHOMEEN™ S/12 (bis [2-hydroxyethyl]¬soyamine); ETHOMEEN™ T/12 (bis[2-hydroxyethyl]-tallow-amine);ETHOMEEN™ T/15 (polyoxyethylene-[5]tallowamine); ETHOMEEN™ O/12(bis[2-hydroxyethyl] oleyl-amine); ETHOMEEN™ 18/12(bis[2-hydroxyethyl]¬octadecylamine); and ETHOMEEN™ 18/25(polyoxyethylene[15]¬octadecylamine). Fatty amines and ethoxylated fattyamines are also described in U.S. Pat. No. 4,741,848. Dihydroxyethyltallowamine (commercially sold as ENT-12™) is included in these types ofamines.

The (viii) alkoxylated fatty amines, and (v) fatty amines themselves(such as oleylamine and dihydroxyethyl tallowamine) may be useful asfriction modifiers in this disclosure. Such amines are commerciallyavailable.

Both borated and unborated fatty acid esters of glycerol can be used asfriction modifiers. The (vii) borated fatty acid esters of glycerol areprepared by borating a fatty acid ester of glycerol with boric acid withremoval of the water of reaction. In an embodiment, there is sufficientboron present such that each boron will react with from 1.5 to 2.5hydroxyl groups present in the reaction mixture. The reaction may becarried out at a temperature in the range of about 60° C. to about 135°C., in the absence or presence of any suitable organic solvent, such asmethanol, benzene, xylenes, toluene, or oil.

The (vi) fatty acid esters of glycerol themselves can be prepared by avariety of methods well known in the art. Many of these esters, such asglycerol monooleate and glycerol tallowate, are manufactured on acommercial scale. In a particular embodiment, the esters are oil-solubleand prepared from C8 to C22 fatty acids or mixtures thereof, such as arefound in natural products and as are described in greater detail below.In an embodiment, fatty acid monoesters of glycerol used, although,mixtures of mono- and diesters may be used. For example, commercialglycerol monooleate may contain a mixture of 45% to 55% by weightmonoester and 55% to 45% diester.

Fatty acids can be used in preparing the above glycerol esters; they canalso be used in preparing their (x) metal salts, (ii) amides, and (xii)imidazolines, any of which can also be used as friction modifiers. In anembodiment, the fatty acids are those containing 10 to 24 carbon atoms,such as those containing 12 to 18 carbon atoms. The acids can bebranched or straight-chain, saturated or unsaturated. In someembodiments, the acids are straight-chain acids. In other embodiments,the acids are branched. Suitable acids include decanoic, oleic, stearic,isostearic, palmitic, myristic, palmitoleic, linoleic, lauric, andlinolenic acids, and the acids from the natural products tallow, palmoil, olive oil, peanut oil, corn oil, coconut oil and Neat's foot oil.In certain embodiments, the acid is oleic acid. In other embodiments,the metal salts include zinc and calcium salts. Examples are overbasedcalcium salts and basic oleic acid-zinc salt complexes, such as zincoleate, which can be represented by the formula Zn₄Oleate₆O₁. In anembodiment, the amides are those prepared by condensation with ammoniaor with primary or secondary amines such as ethylamine anddiethanolamine. Fatty imidazolines are the cyclic condensation productof an acid with a diamine or polyamine, such as a polyethylenepolyamine.The imidazolines may be represented by the structure:

wherein: R is an alkyl group; and R′ is hydrogen or a hydrocarbyl groupor a substituted hydrocarbyl group, including —(CH₂CH₂NH)_(n)— groups,wherein n is an integer from 1 to 4. In an embodiment, the frictionmodifier is the condensation product of a C10 to C24 fatty acid with apolyalkylene polyamine, and in particular, the product of isostearicacid with tetraethylenepentamine.

The condensation products of carboxylic acids and polyalkyleneamines(xiii) may be imidazolines or amides. They may be derived from any ofthe carboxylic acids described above and any of the polyamines describedherein.

Sulfurized olefins (xi) are well known commercial materials used asfriction modifiers. A particularly sulfurized olefin utilized herein isone which is prepared in accordance with the detailed teachings of U.S.Pat. Nos. 4,957,651 and 4,959,168. Described therein is a co-sulfurizedmixture of 2 or more reactants selected from the group consisting of (1)at least one fatty acid ester of a polyhydric alcohol, (2) at least onefatty acid, (3) at least one olefin, and (4) at least one fatty acidester of a monohydric alcohol. Reactant (3), the olefin component,comprises at least one olefin. This olefin is may be an aliphaticolefin, which usually will contain 4 to 40 carbon atoms, e.g. from 8 to36 carbon atoms. For example, terminal olefins, or alpha-olefins,including those having from 12 to 20 carbon atoms, may be utilized.Mixtures of these olefins are commercially available, and such mixturesare contemplated for use in this disclosure. The co-sulfurized mixtureof two or more of the reactants, is prepared by reacting the mixture ofappropriate reactants with a source of sulfur. The mixture to besulfurized can contain about 10 to about 90 parts of Reactant (1), orabout 0.1 to about 15 parts by weight of Reactant (2); or about 10 toabout 90 parts (e.g. about 15 to about 60 parts or about 25 to about 35parts) by weight of Reactant (3), or about 10 to about 90 parts byweight of reactant (4). The mixture, in the present disclosure, includesReactant (3) and at least one other member of the group of reactantsidentified as Reactants (1), (2) and (4). The sulfurization reaction maybe effected at an elevated temperature with agitation and optionally inan inert atmosphere and in the presence of an inert solvent. Thesulfurizing agents useful in the process of the present disclosureinclude elemental sulfur, which maybe hydrogen sulfide, sulfur halideplus sodium sulfide, and a mixture of hydrogen sulfide and sulfur orsulfur dioxide. For example, about 0.5 to about 3 moles of sulfur areemployed per mole of olefinic bonds. Sulfurized olefins may also includesulfurized oils, such as vegetable oil, lard oil, oleic acid and olefinmixtures.

Metal salts of alkyl salicylates (xiii) include calcium and other saltsof long chain (e.g. C12 to C16) alkyl-substituted salicylic acids.

Amine salts of alkylphosphoric acids (xiv) include salts of oleyl andother long chain esters of phosphoric acid, with amines as describedbelow. Useful amines in this regard are tertiary-aliphatic primaryamines, sold under the tradename Primene™.

In some embodiments, the friction modifier is a fatty acid or fatty oil,a metal salt of a fatty acid, a fatty amide, a sulfurized fatty oil orfatty acid, an alkyl phosphate, an alkyl phosphate amine salt; acondensation product of a carboxylic acid and a polyamine, a boratedfatty epoxide, a fatty imidazoline, or combinations thereof.

In other embodiments, the friction modifier may be the condensationproduct of isostearic acid and tetraethylene pentamine, the condensationproduct of isostearic acid and 1-[tris(hydroxymethyl)]methylamine,borated polytetradecyloxirane, zinc oleate, hydroxylethyl-2-heptadecenylimidazoline, dioleyl hydrogen phosphate, C14-C18 alkyl phosphate or theamine salt thereof, sulfurized vegetable oil, sulfurized lard oil,sulfurized oleic acid, sulfurized olefins, oleyl amide, glycerolmonooleate, soybean oil, or mixtures thereof.

In still other embodiments, the friction modifier may be glycerolmonooleate, oleylamide, the reaction product of isostearic acid and2-amino-2-hydroxymethyl-1,3-propanediol, sorbitan monooleate,9-octadecenoic acid, isostearyl amide, isostearyl monooleate orcombinations thereof.

Although their presence is not required to obtain the benefit of thepresent disclosure, friction modifiers may be present in an amount fromzero to about 2 wt. % (e.g., about 0.01 wt. % to about 1.5 wt. %) of thecomposition of the present disclosure. These ranges may apply to theamounts of individual friction modifier present in the composition or tothe total friction modifier component in the compositions, which mayinclude a mixture of two or more friction modifiers.

Many friction modifiers tend to also act as emulsifiers. This is oftendue to the fact that friction modifiers often have non-polar fatty tailsand polar head groups.

The composition of the present disclosure exhibits desired properties,e.g., wear control, in the presence or absence of a friction modifier.

Although their presence is not required to obtain the benefit of thisdisclosure, the friction modifier or friction modifiers may be presentin an amount of about 0.01 weight percent to about 5 weight percent(e.g. about 0.1 weight percent to about 2.5 weight percent, or about 0.1weight percent to about 1.5 weight percent, or about 0.1 weight percentto about 1 weight percent). Concentrations of molybdenum-containingmaterials are often described in terms of Mo metal concentration.Advantageous concentrations of Mo may range from about 25 ppm to about700 ppm or more (e.g. about 50 to about 200 ppm). Friction modifiers ofall types may be used alone or in mixtures with the materials of thisdisclosure. Often mixtures of two or more friction modifiers, ormixtures of friction modifier(s) with alternate surface activematerial(s), are also desirable.

Molybdenum-Containing Compounds (Friction Reducers)

Illustrative molybdenum-containing friction reducers useful in thedisclosure include, for example, an oil-soluble decomposable organomolybdenum compound, such as Molyvan™ 855 which is an oil solublesecondary diarylamine defined as substantially free of active phosphorusand active sulfur. The Molyvan™ 855 is described in Vanderbilt'sMaterial Data and Safety Sheet as an organomolybdenum compound having adensity of 1.04 and viscosity at 100° C. of 47.12 cSt. The organomolybdenum compounds may be useful because of their superior solubilityand effectiveness.

Another illustrative molybdenum-containing compound is Molyvan™ L, whichis sulfonated oxymolybdenum dialkyldithiophosphate described in U.S.Pat. No. 5,055,174 hereby incorporated by reference.

Molyvan™ A made by R. T. Vanderbilt Company, Inc., New York, N.Y., USA,is also an illustrative molybdenum-containing compound, which containsabout 28.8 wt. % Mo, 31.6 wt. % C, 5.4 wt. % H., and 25.9 wt. % S. Alsouseful are Molyvan™ 855, Molyvan™ 822, Molyvan™ 856, and Molyvan™ 807.

Also useful is Sakura Lube™ 500, which is more soluble Modithiocarbamate containing lubricant additive obtained from Asahi DenkiCorporation and comprised of about 20.2 wt. % Mo, 43.8 wt. % C, 7.4 wt.% H, and 22.4 wt. % S. Sakura Lube™ 300, a low sulfur molybdenumdithiophosphate having a molybdenum to sulfur ratio of 1:1.07, is amolybdenum-containing compound useful in this disclosure.

Also useful is Molyvan™ 807, a mixture of about 50 wt. % molybdenumditridecyldithyocarbonate, and about 50 wt. % of an aromatic oil havinga specific gravity of about 38.4 SUS and containing about 4.6 wt. %molybdenum, also manufactured by R. T. Vanderbilt and marketed as anantioxidant and antiwear additive.

Other sources are molybdenum Mo(Co)₆, and molybdenum octoate,MoO(C₇H₁₅CO₂)₂ containing about 8 wt-% Mo marketed by Aldrich ChemicalCompany, Milwaukee, Wis. and molybdenum naphthenethioctoate marketed byShephard Chemical Company, Cincinnati, Ohio.

Inorganic molybdenum compounds, such as molybdenum sulfide andmolybdenum oxide, are substantially less preferred than the organiccompounds as described in Molyvan™ 855, Molyvan™ 822, Molyvan™ 856, andMolyvan™ 807.

Illustrative molybdenum-containing compounds useful in this disclosureare disclosed, for example, in U.S. Patent Application Publication No.2003/0119682, which is incorporated herein by reference.

Organo molybdenum-nitrogen complexes may also be included in theformulations of the present disclosure. The term “organo molybdenumnitrogen complexes” embraces the organo molybdenum nitrogen complexesdescribed in U.S. Pat. No. 4,889,647. The complexes are reactionproducts of a fatty oil, dithanolamine and a molybdenum source. Specificchemical structures have not been assigned to the complexes. U.S. Pat.No. 4,889,647 reports an infrared spectrum for an exemplary reactionproduct of that disclosure; the spectrum identifies an ester carbonylband at 1740 cm 1 and an amide carbonyl band at 1620 cm 1. The fattyoils are glyceryl esters of higher fatty acids containing at least 12carbon atoms up to 22 carbon atoms or more. The molybdenum source is anoxygen-containing compound such as ammonium molybdates, molybdenumoxides and mixtures.

Other organo molybdenum complexes which can be used in the presentdisclosure are tri nuclear molybdenum sulfur compounds described in EP 1040 115 and WO 99/31113, and the molybdenum complexes described in U.S.Pat. No. 4,978,464.

Although their presence is not required to obtain the benefit of thepresent disclosure, molybdenum-containing additives may be used in anamount of from zero to about 5.0 (e.g., ≤about 5, ≤about 4, ≤about 3,≤about 2, or ≤about 1) percent by mass of the composition of the presentdisclosure. For example, the dosage may be up to about 3,000 ppm bymass, such as from about 100 ppm to about 2,500 ppm by mass, from about300 to about 2,000 ppm by mass, or from about 300 to about 1,500 ppm bymass of molybdenum.

Borated Ester Compounds (Corrosion Inhibitors)

In any aspect or embodiment described herein, the composition of thepresent disclosure can have at least one (e.g., 1, 2, 3, or 4, or more)borated-ester compound. Illustrative boron-containing compounds usefulin the disclosure include, for example, a borate ester, a boric acid,other boron compounds, such as a boron oxide. The boron compound ishydrolytically stable and is utilized for improved antiwear and performsas a rust and corrosion inhibitor for copper bearings and other metalengine components. The borated ester compound acts as an inhibitor forcorrosion of metal to prevent corrosion of either ferrous or non-ferrousmetals (e.g. copper, bronze, brass, titanium, aluminum and the like) orboth, present in concentrations in which they are effective ininhibiting corrosion.

Patents describing techniques for making basic salts of sulfonic,carboxylic acids and mixtures thereof include U.S. Pat. Nos. 5,354,485;2,501,731; 2,616,911; 2,777,874; 3,384,585; 3,320,162; 3,488,284; and3,629,109. The disclosures of these patents are incorporated herein byreference. Methods of preparing borated overbased compositions are foundin U.S. Pat. Nos. 4,744,920; 4,792,410; and PCT publication WO 88/03144.The disclosures of these references are incorporated herein byreference. The oil-soluble neutral or basic salts of alkali or alkalineearth metals salts may also be reacted with a boron compound.

An illustrative borate ester utilized in this disclosure is manufacturedby Exxon-Mobil USA under the product designation of (“MCP 1286”) andMOBIL ADC700. Test data show the viscosity at 100° C. using the D-445method is 2.9 cSt; the viscosity at 40° C. using the D-445 method is11.9; the flash point using the D-93 method is 146; the pour point usingthe D-97 method is −69; and the percent boron as determined by the ICPmethod is 5.3%. The borated ester (Vanlube™ 289), which is marketed asan antiwear/antiscuff additive and friction reducer, is an exemplaryborate ester useful in the disclosure.

An illustrative borate ester useful in this disclosure is the reactionproduct obtained by reacting about 1 mole fatty oil, about 1.0 to 2.5moles diethanolamine followed by subsequent reaction with boric acid toyield about 0.1 to 3 percent boron by mass. It is believed that thereaction products may include one or both of the following two primarycomponents, with the further listed components being possible componentswhen the reaction is pushed toward full hydration:

wherein Y represents a fatty oil residue. In an embodiment, the fattyoils are glyceryl esters of higher fatty acids containing at least 12carbon atoms (e.g. 22 carbon atoms or more). Such esters are commonlyknown as vegetable and animal oils. Vegetable oils that may be usedinclude oils derived from coconut, corn, cottonseed, linseed, peanut,soybean and sunflower seed. Similarly, animal fatty oils such as tallowmay be used.

The source of boron is boric acid or materials that afford boron and arecapable of reacting with the intermediate reaction product of fatty oiland diethanolamine to form a borate ester composition.

While the above organoborate ester composition is specifically discussedabove, it should be understood that other organoborate estercompositions should also function with similar effect in the presentdisclosure, such as those set forth in U.S. Patent ApplicationPublication No. 2003/0119682, which is incorporated herein by reference.In addition, dispersions of borate salts, such as potassium borate, mayalso be useful.

Other illustrative organoborate compositions useful in this disclosureare disclosed, for example, in U.S. Patent Application Publication No.2008/0261838, which is incorporated herein by reference.

In addition, other illustrative organoborate compositions useful in thisdisclosure are disclosed, for example, U.S. Pat. Nos. 4,478,732,4,406,802, 4,568,472 on borated mixed hydroxyl esters, alkoxylatedamides, and amines; U.S. Pat. No. 4,298,486 on borated hydroxyethylimidazolines; U.S. Pat. No. 4,328,113 on borated alkyl amines and alkyldiamines; U.S. Pat. No. 4,370,248 on borated hydroxyl-containing esters,including GMO; U.S. Pat. No. 4,374,032 on borated hydroxyl-containinghydrocarbyl oxazolines; U.S. Pat. No. 4,376,712 on borated sorbitanesters; U.S. Pat. No. 4,382,006 on borated ethoxylated amines; U.S. Pat.No. 4,389,322 on ethoxylated amides and their borates;

U.S. Pat. No. 4,472,289 on hydrocarbyl vicinal diols and alcohols andester mixtures and their borates; U.S. Pat. No. 4,522,734 on borates ofhydrolyzed hydrocarbyl epoxides; U.S. Pat. No. 4,537,692 on etherdiamineborates; U.S. Pat. No. 4,541,941 on mixtures containing vicinal diolsand hydroxyl substituted esters and their borates; U.S. Pat. No.4,594,171 on borated mixtures of various hydroxyl and/or nitrogencontaining borates; and U.S. Pat. No. 4,692,257 on various boratedalcohols/diols, all of which are incorporated herein by reference.

Although their presence is not required to obtain the benefit of thisdisclosure, boron-containing compounds may be present in an amount offrom zero to about 10.0% percent (e.g. from about 0.01% to about 5% orfrom about 0.1% to about 3.0%) by weight of the composition of thepresent disclosure. An effective elemental boron range of up to about1000 ppm or less than about 1% elemental boron. Thus, in an embodiment,a concentration of elemental boron is from about 100 to about 1000 ppm(e.g. from about 100 to about 300 ppm).

When the grease composition of the present disclosure includes one ormore of the additives discussed herein, the additive(s) are blended intothe composition in an amount sufficient for it to perform its intendedfunction.

The weight percent (wt. %) indicated herein is based on the total weightof the composition of the present disclosure. It is noted that many ofthe additives are shipped from the additive manufacturer as aconcentrate, containing one or more additives together, with a certainamount of base oil diluents. Accordingly, the weight amounts mentionedherein are directed to the amount of active ingredient (that is thenon-diluent portion of the ingredient).

In a further aspect, the present disclosure provides a method ofpreparing a grease composition with improved structural stability inhigh shear, hot and wet environments, and also improved low temperaturestarting torque and thereby better wear and load protection inapplications where a cold start of equipment is needed. The methodcomprises mixing at least one base oil, at least one thickenercomprising a polyurea, and at least one elastomeric triblock copolymer,each as described herein.

The grease of the present disclosure may be made in a batch process withcontactor followed by finishing kettle or in a continuous grease makingprocess, both of which are well known and widely used. In batch greasemaking, the grease is usually prepared by chemically reacting andmechanically dispersing the thickener components in the lubricating oilfor from about 1 to about 8 hours or more (e.g., from about 3 to about 6hours) followed by heating at elevated temperature (e.g., from about140° C. to about 225° C. depending upon the particular thickener used)until the mixture thickens. In some cases (e.g. a simple lithiumgrease), a preformed thickener can be used. The mixture is then cooledto ambient temperature (typically about 60° C.) during which timeperformance additive(s) or additive package is added.

The elastomeric triblock copolymer may be incorporated into asemi-finished grease containing the base oil and thickener possibly withthe additive package present or added earlier as a blend component. Theelastomeric triblock copolymer is typically viscous liquid, semi-liquidor, quite often powder and in order to facilitate blending into thegrease base, it may be necessary in the case of the powder materials or,in the case of the liquids, desirable, to heat the elastomeric triblockcopolymer prior to incorporation into the other grease components. In abatch type process, the elastomeric triblock copolymer may be liquefiedprior to being added to the contactor in which the components of thethickener are to be reacted in the presence of the base oil although ithas been found preferable to add powdered elastomeric triblock copolymerto the finishing kettle that is at a high enough temperature to melt theelastomeric triblock copolymer but sufficiently low to avoid exposure tothe higher temperatures typically prevailing in the contactor during thesoap making step. Additionally, this sequence avoids subjecting theelastomeric triblock copolymer to high temperature/high shear conditionsof the contactor likely to degrade the elastomeric triblock copolymerproperties. The temperatures in the finishing kettle will typically be120° C. or higher so as to preclude separation of the elastomerictriblock copolymer before it becomes incorporated into the grease mass.In a continuous grease making process, the elastomeric triblockcopolymer may be added as one of the blend components to where the linewhere the temperature/shear regime is suitable for the particularelastomeric triblock copolymer.

The grease composition can be mixed, blended, or milled in any number ofways including external mixers, roll mills, internal mixers, Banburymixers, screw extruders, augers, colloid mills, homogenizers, and thelike. A continuous grease making process for making, e.g., lithiumcomplex greases is described to U.S. Pat. No. 7,829,512.

The grease composition has at least one of the following: less than orequal to about 1.25 wt. % of the elastomeric triblock copolymer, about0.5 wt. % to about 20 wt. % of the thickener, about 50 wt. % to about 90wt. % of the base oil, less than or equal to about 1 wt. % of additives,or a combination thereof.

The grease composition may have at least one of the following: less thanor equal to about 1 wt. % of the elastomeric triblock copolymer, about 1wt. % to about 3 wt. % of the thickener, about 70 wt. % to about 85 wt.% of the base oil, less than or equal to about 0.25 wt. % of additives,or a combination thereof.

The composition prepared according to the method of the presentdisclosure may have at least one of: the composition provides minimalchange in penetration point as determined by ASTM-D7342; the compositionprovides reduced starting and running torque as determined byASTM-D1478; or both.

The grease composition may further comprise, as described herein, atleast one performance additive selected from the group consisting ofanticorrosive agent or corrosion inhibitor, an extreme pressureadditive, an antiwear agent, a pour point depressants, an antioxidant oroxidation inhibitor, a rust inhibitor, a metal deactivator, adispersant, a demulsifier, a dye or colorant/chromophoric agent, a sealcompatibility agent, a friction modifier, a viscosity modifier/improver,a viscosity index improver, or combinations thereof.

The present disclosure is further illustrated by the following examples,which should not be construed as limiting. The data below demonstratesthat the compositions of the present disclosure provide the surprisingand unexpected effect of having significantly improved structuralstability and resistance to breaking down, relative to other greases,under extreme conditions, such as high shear conditions in hot, wetenvironments. Those skilled in the art will recognize that thedisclosure may be practiced with variations on the disclosed structures,materials, compositions and methods, and such variations are regarded aswithin the ambit of the disclosure.

EXAMPLES

Grease formulations were prepared as described herein. All of theingredients used herein are commercially available.

The elastomeric triblock copolymer used in the grease formulations(i.e., Polymer A) had a general configuration A-B-A, in which A was arelatively hydrophobic polymer block and B was a relatively hydrophilicpolymer block, and in which A formed less than 50% by weight of thetotal molecular weight of the elastomeric triblock copolymer.

The performance additive package used in the grease formulationsincluded conventional additives in conventional amounts. Conventionaladditives used in the formulations were one or more of an anticorrosiveagent or corrosion inhibitor, an extreme pressure additive, an antiwearagent, a pour point depressants, an antioxidant or oxidation inhibitor,a rust inhibitor, a metal deactivator, a dispersant, a demulsifier, adye or colorant/chromophoric agent, a seal compatibility agent, afriction modifier, a viscosity modifier/improver, and a viscosity indeximprover.

The grease formulations were tested for structural stability andresistance to breaking down under high shear conditions in accordancewith ASTM D7342.

The grease formulations were also tested for low temperature startingand running torque in accordance with ASTM D1478.

FIGS. 1 and 3 show examples of a polyurea grease formulated with the useof only 0.5-2.2% of the ABA triblock copolymer having compositionalcharacteristics described above that exhibits a significant improvementin wet structural stability of greases as measured by ASTM D7342.

ASTM D7342 is described as testing the prolonged worked and shearstability of grease in the presence of water. In this test method thepenetration (consistency) of the grease is measured before and after thegrease is subjected to a 100,000 strokes of an extremely high sheargrease worker equipment in a wet environment. The difference inpenetration (consistency) of grease before and after it is subjected tohigh shear over long periods of time (typically 28 hours) is anexcellent and direct measure of the structural stability of greases inhigh shear wet environments.

FIG. 1 shows the full scale change in penetration of grease before andafter the test. It can be seen that while the base polyurea grease had asignificant reduction in penetration (consistency) due to breaking downof the grease structure under high shear/wet environment, the greasemodified with various levels of ABA triblock copolymer of thecompositional characteristics previously described had minimal change inits penetration (consistency). Thus, the grease compositions of thisdisclosure provide a new polyurea grease with excellent structuralstability.

FIGS. 1 and 4 also show that the grease composition reduced the startingtorque requirement to run a ball bearing using the described greases inASTM D1478 test measured at low temperatures of −40 C. The runningtorque for polyurea greases is already very low in this particular testand a significant change in the running torque requirement to run a ballbearing using the described greases in ASTM D1478 test (measured at lowtemperatures of −40C), was not seen.

FIG. 2 describes the use of the same ABA triblock copolymer (Polymer A)with compositional characteristics previously described, additized in abase lithium grease. In contrast to polyurea greases, the wet structuralstability (ASTM D7342) of the lithium grease compositions using the ABAtriblock copolymer were not seen to change significantly from theoriginal base grease. In another contrast to the polyurea greasehowever, the low temperature running as well as starting torquerequirement of a ball bearing using the lithium based greases in FIG. 2was surprisingly seen to improve significantly with the use ofinnovative lithium base greases using the ABA triblock copolymer withcompositional characteristics previously described.

Thus, the grease compositions described here provide improvement in lowtemperature properties of both polyurea greases as well as lithiumgreases.

FIG. 1 shows polyurea grease compositions and test results of wetstructural stability as measured by ASTM D7342, and low temperaturestarting and running torque as measured by ASTM D1478.

FIG. 2 shows lithium grease compositions and test results of wetstructural stability as measured by ASTM D7342, and low temperaturestarting and running torque as measured by ASTM D1478.

FIG. 3 graphically shows polyurea grease compositions and test resultsof wet structural stability as measured by ASTM D7342. The experimentaldata is from FIG. 1.

FIG. 4 graphically shows polyurea grease compositions and test resultsof low temperature starting torque as measured by ASTM D1478. Theexperimental data is from FIG. 1.

As shown in the examples, the polyurea grease compositions of thisdisclosure perform well in high shear, hot and wet environments andprovide a longer application life as well as reduce friction and wear inthe metal parts that the grease is lubricating, thereby leading tobetter energy efficiency and equipment reliability and life.

As also shown in the examples, the polyurea grease compositions of thisdisclosure have desired low temperature properties as measured byimprovement in starting torque for the grease in the ASTM D1478 standardtest method for low temperature torque for ball bearing greases.

As further shown in the examples, the lithium and lithium complex greasecompositions of this disclosure have desired low temperature propertiesas measured by improvement in starting and running torque for the greasein the ASTM D1478 standard test method for low temperature torque forball bearing greases, even though an improvement in structural stabilityof lithium/lithium complex greases under wet, hot and high shearconditions is not realized.

PCT and EP Clauses:

1. A grease composition comprising: at least one base oil; at least onenon-soap thickener; and at least one elastomeric triblock copolymer ofthe general configuration A-B-A; wherein A is a relatively hydrophobicpolymer block and B is a relatively hydrophilic polymer block; andwherein A forms less than 50% by weight of the total molecular weight ofthe elastomeric triblock copolym

2. The grease composition of clause 1 wherein the at least one non-soapthickener comprises a polyurea.

3. The grease composition of clauses 1 and 2 wherein, when used underhigh shear conditions, structural stability and resistance to breakingdown in accordance with ASTM D7342 is improved, as compared tostructural stability and resistance to breaking down achieved using agrease composition containing other than said polyurea.

4. The grease composition of clauses 1-3 wherein, when used in lowtemperature conditions, low temperature starting torque in accordancewith ASTM D1478 is improved, as compared to low temperature startingtorque in accordance with ASTM D1478 achieved using a grease compositioncontaining other than said polyurea.

5. The grease composition of clauses 1-4 wherein the at least oneelastomeric triblock copolymer comprises block segments of styrenemonomer units and rubber monomer and/or comonomer units.

6. The grease composition of clauses 1-5 wherein the at least oneelastomeric triblock copolymer comprises polystyrene end blocks andelastomeric midblocks.

7. The grease composition of clauses 1-6 wherein the at least oneelastomeric triblock copolymer comprisesstyrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS).

8. A grease composition comprising: at least one base oil; at least onesoap thickener; and at least one elastomeric triblock copolymer of thegeneral configuration A-B-A; wherein A is a relatively hydrophobicpolymer block and B is a relatively hydrophilic polymer block; andwherein A forms less than 50% by weight of the total molecular weight ofthe elastomeric triblock copolymer.

9. The grease composition of clause 8 wherein the at least one soapthickener comprises a lithium soap or lithium salt/soap complex.

10. The grease composition of clauses 8 and 9 wherein, when used in lowtemperature conditions, low temperature starting and running torque inaccordance with ASTM D1478 are improved, as compared to low temperaturestarting and running torque in accordance with ASTM D1478 achieved usinga grease composition containing other than said lithium soap or lithiumsalt/soap complex.

11. The grease composition of clauses 8-10 grease composition of claim14 wherein the at least one elastomeric triblock copolymer comprisesblock segments of styrene monomer units and rubber monomer and/orcomonomer units.

12. The grease composition of clauses 8-11 wherein the at least oneelastomeric triblock copolymer comprises polystyrene end blocks andelastomeric midblocks.

13. The grease composition of clauses 8-12 wherein the at least oneelastomeric triblock copolymer comprisesstyrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS).

14. A method of preparing a grease composition comprising mixing atleast one base oil, at least one non-soap thickener, and at least oneelastomeric triblock copolymer of the general configuration A-B-A;wherein A is a relatively hydrophobic polymer block and B is arelatively hydrophilic polymer block; and wherein A forms less than 50%by weight of the total molecular weight of the elastomeric triblockcopolymer.

15. A method of preparing a grease composition comprising mixing atleast one base oil, at least one soap thickener, and at least oneelastomeric triblock copolymer of the general configuration A-B-A;wherein A is a relatively hydrophobic polymer block and B is arelatively hydrophilic polymer block; and wherein A forms less than 50%by weight of the total molecular weight of the elastomeric triblockcopolymer.

All patents and patent applications, test procedures (such as ASTMmethods, UL methods, and the like), and other documents cited herein arefully incorporated by reference to the extent such disclosure is notinconsistent with this disclosure and for all jurisdictions in whichsuch incorporation is permitted.

When numerical lower limits and numerical upper limits are listedherein, ranges from any lower limit to any upper limit are contemplated.While the illustrative embodiments of the disclosure have been describedwith particularity, it will be understood that various othermodifications will be apparent to and can be readily made by thoseskilled in the art without departing from the spirit and scope of thedisclosure. Accordingly, it is not intended that the scope of the claimsappended hereto be limited to the examples and descriptions set forthherein but rather that the claims be construed as encompassing all thefeatures of patentable novelty which reside in the present disclosure,including all features which would be treated as equivalents thereof bythose skilled in the art to which the disclosure pertains.

The present disclosure has been described above with reference tonumerous embodiments and specific examples. Many variations will suggestthemselves to those skilled in this art in light of the above detaileddescription. All such obvious variations are within the full intendedscope of the appended claims.

1. A grease composition comprising: at least one base oil; at least onenon-soap thickener; and at least one elastomeric triblock copolymer ofthe general configuration A-B-A; wherein A is a relatively hydrophobicpolymer block and B is a relatively hydrophilic polymer block; andwherein A forms less than 50% by weight of the total molecular weight ofthe elastomeric triblock copolymer.
 2. The grease composition of claim 1wherein the at least one non-soap thickener comprises a polyurea.
 3. Thegrease composition of claim 2 wherein, when used under high shearconditions, structural stability and resistance to breaking down inaccordance with ASTM D7342 is improved, as compared to structuralstability and resistance to breaking down achieved using a greasecomposition containing other than said polyurea.
 4. The greasecomposition of claim 2 wherein, when used in low temperature conditions,low temperature starting torque in accordance with ASTM D1478 isimproved, as compared to low temperature starting torque in accordancewith ASTM D1478 achieved using a grease composition containing otherthan said polyurea.
 5. The grease composition of claim 1 wherein the atleast one elastomeric triblock copolymer comprises block segments ofstyrene monomer units and rubber monomer and/or comonomer units.
 6. Thegrease composition of claim 1 wherein the at least one elastomerictriblock copolymer comprises polystyrene end blocks and elastomericmidblocks.
 7. The grease composition of claim 1 wherein the at least oneelastomeric triblock copolymer comprisesstyrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS). 8.The grease composition of claim 1 wherein the at least one base oilcomprises a Group I, Group II, Group III, Group IV, Group V base oil,and combinations thereof.
 9. The grease composition of claim 1 furthercomprising at least one performance additive selected from the groupconsisting of an anticorrosive agent or corrosion inhibitor, an extremepressure additive, an antiwear agent, a pour point depressants, anantioxidant or oxidation inhibitor, a rust inhibitor, a metaldeactivator, a dispersant, a demulsifier, a dye or colorant/chromophoricagent, a seal compatibility agent, a friction modifier, a viscositymodifier/improver, a viscosity index improver, and combinations thereof.10. The grease composition of claim 1 wherein the at least one base oilis present in an amount of from 50 to 95 weight percent, based on thetotal weight of the grease composition.
 11. The grease composition ofclaim 1 wherein the at least one non-soap thickener is present in anamount of from 0.5 to 20 weight percent, based on the total weight ofthe grease composition.
 12. The grease composition of claim 1 whereinthe at least one elastomeric triblock copolymer is present in an amountof from 0.5 to 2.5 weight percent, based on the total weight of thegrease composition.
 13. The grease composition of claim 9 wherein theone or more performance additives are present in an amount of from 0.1to 10 weight percent, based on the total weight of the greasecomposition.
 14. A grease composition comprising: at least one base oil;at least one soap thickener; and at least one elastomeric triblockcopolymer of the general configuration A-B-A; wherein A is a relativelyhydrophobic polymer block and B is a relatively hydrophilic polymerblock; and wherein A forms less than 50% by weight of the totalmolecular weight of the elastomeric triblock copolymer.
 15. The greasecomposition of claim 14 wherein the at least one soap thickenercomprises a lithium soap or lithium salt/soap complex.
 16. The greasecomposition of claim 15 wherein, when used in low temperatureconditions, low temperature starting and running torque in accordancewith ASTM D1478 are improved, as compared to low temperature startingand running torque in accordance with ASTM D1478 achieved using a greasecomposition containing other than said lithium soap or lithium salt/soapcomplex.
 17. The grease composition of claim 14 wherein the at least oneelastomeric triblock copolymer comprises block segments of styrenemonomer units and rubber monomer and/or comonomer units.
 18. The greasecomposition of claim 14 wherein the at least one elastomeric triblockcopolymer comprises polystyrene end blocks and elastomeric midblocks.19. The grease composition of claim 14 wherein the at least oneelastomeric triblock copolymer comprisesstyrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS). 20.The grease composition of claim 14 wherein the at least one base oilcomprises a Group I, Group II, Group III, Group IV, Group V base oil,and combinations thereof.
 21. The grease composition of claim 14 furthercomprising at least one performance additive selected from the groupconsisting of an anticorrosive agent or corrosion inhibitor, an extremepressure additive, an antiwear agent, a pour point depressants, anantioxidant or oxidation inhibitor, a rust inhibitor, a metaldeactivator, a dispersant, a demulsifier, a dye or colorant/chromophoricagent, a seal compatibility agent, a friction modifier, a viscositymodifier/improver, a viscosity index improver, and combinations thereof.22. The grease composition of claim 14 wherein the at least one base oilis present in an amount of from 50 to 95 weight percent, based on thetotal weight of the grease composition.
 23. The grease composition ofclaim 14 wherein the at least one soap thickener is present in an amountof from 0.5 to 20 weight percent, based on the total weight of thegrease composition.
 24. The grease composition of claim 14 wherein theat least one elastomeric triblock copolymer is present in an amount offrom 0.5 to 2.5 weight percent, based on the total weight of the greasecomposition.
 25. The grease composition of claim 21 wherein the one ormore performance additives are present in an amount of from 0.1 to 10weight percent, based on the total weight of the grease composition. 26.A method of preparing a grease composition comprising mixing at leastone base oil, at least one non-soap thickener, and at least oneelastomeric triblock copolymer of the general configuration A-B-A;wherein A is a relatively hydrophobic polymer block and B is arelatively hydrophilic polymer block; and wherein A forms less than 50%by weight of the total molecular weight of the elastomeric triblockcopolymer.
 27. The method of claim 26 wherein the at least one non-soapthickener comprises a polyurea.
 28. The method of claim 27 wherein, whenused under high shear conditions, structural stability and resistance tobreaking down in accordance with ASTM D7342 is improved, as compared tostructural stability and resistance to breaking down achieved using agrease composition containing other than said polyurea.
 29. The methodof claim 27 wherein, when used in low temperature conditions, lowtemperature starting torque in accordance with ASTM D1478 is improved,as compared to low temperature starting torque in accordance with ASTMD1478 achieved using a grease composition containing other than saidpolyurea.
 30. The method of claim 26 wherein the at least oneelastomeric triblock copolymer comprises block segments of styrenemonomer units and rubber monomer and/or comonomer units.
 31. The methodof claim 26 wherein the at least one elastomeric triblock copolymercomprises polystyrene end blocks and elastomeric midblocks.
 32. Themethod of claim 26 wherein the at least one elastomeric triblockcopolymer comprises styrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS). 33.The method of claim 26 wherein the at least one base oil comprises aGroup I, Group II, Group III, Group IV, Group V base oil, andcombinations thereof.
 34. The method of claim 26 further comprisingmixing at least one performance additive selected from the groupconsisting of an anticorrosive agent or corrosion inhibitor, an extremepressure additive, an antiwear agent, a pour point depressants, anantioxidant or oxidation inhibitor, a rust inhibitor, a metaldeactivator, a dispersant, a demulsifier, a dye or colorant/chromophoricagent, a seal compatibility agent, a friction modifier, a viscositymodifier/improver, a viscosity index improver, and combinations thereof.35. The method of claim 26 wherein the at least one base oil is presentin an amount of from 50 to 95 weight percent, based on the total weightof the grease composition.
 36. The method of claim 26 wherein the atleast one non-soap thickener is present in an amount of from 0.5 to 20weight percent, based on the total weight of the grease composition. 37.The method of claim 26 wherein the at least one elastomeric triblockcopolymer is present in an amount of from 0.5 to 2.5 weight percent,based on the total weight of the grease composition.
 38. The method ofclaim 34 wherein the one or more performance additives are present in anamount of from 0.1 to 10 weight percent, based on the total weight ofthe grease composition.
 39. A method of preparing a grease compositioncomprising mixing at least one base oil, at least one soap thickener,and at least one elastomeric triblock copolymer of the generalconfiguration A-B-A; wherein A is a relatively hydrophobic polymer blockand B is a relatively hydrophilic polymer block; and wherein A formsless than 50% by weight of the total molecular weight of the elastomerictriblock copolymer.
 40. The method of claim 39 wherein the at least onesoap thickener comprises a lithium soap or lithium salt/soap complex.41. The method of claim 40 wherein, when used in low temperatureconditions, low temperature starting and running torque in accordancewith ASTM D1478 are improved, as compared to low temperature startingand running torque in accordance with ASTM D1478 achieved using a greasecomposition containing other than said lithium soap or lithium salt/soapcomplex.
 42. The method of claim 39 wherein the at least one elastomerictriblock copolymer comprises block segments of styrene monomer units andrubber monomer and/or comonomer units.
 43. The method of claim 39wherein the at least one elastomeric triblock copolymer comprisespolystyrene end blocks and elastomeric midblocks.
 44. The method ofclaim 39 wherein the at least one elastomeric triblock copolymercomprises styrene-ethylenebutylene-styrene type (S-EB-S),styrene-butadiene-styrene (SBS), or styrene-isoprene-styrene (SIS). 45.The method of claim 39 wherein the at least one base oil comprises aGroup I, Group II, Group III, Group IV, Group V base oil, andcombinations thereof.
 46. The method of claim 39 further comprisingmixing at least one performance additive selected from the groupconsisting of an anticorrosive agent or corrosion inhibitor, an extremepressure additive, an antiwear agent, a pour point depressants, anantioxidant or oxidation inhibitor, a rust inhibitor, a metaldeactivator, a dispersant, a demulsifier, a dye or colorant/chromophoricagent, a seal compatibility agent, a friction modifier, a viscositymodifier/improver, a viscosity index improver, and combinations thereof.47. The method of claim 39 wherein the at least one base oil is presentin an amount of from 50 to 95 weight percent, based on the total weightof the grease composition.
 48. The method of claim 39 wherein the atleast one soap thickener is present in an amount of from 0.5 to 20weight percent, based on the total weight of the grease composition. 49.The method of claim 39 wherein the at least one elastomeric triblockcopolymer is present in an amount of from 0.5 to 2.5 weight percent,based on the total weight of the grease composition.
 50. The method ofclaim 46 wherein the one or more performance additives are present in anamount of from 0.1 to 10 weight percent, based on the total weight ofthe grease composition.